Fabrics and spun yarns comprising polyester staple fiber

ABSTRACT

Disclosed herein are spun yarns comprising melt spun staple fiber comprising a first polymer and a second polymer, wherein the first polymer comprises poly(trimethylene terephthalate) or poly(butylene terephthalate) and the second polymer comprises poly(ethylene terephthalate) or Co-PET, wherein Co-PET is a poly(ethylene terephthalate) copolymer comprising isophthalic acid monomer; and wherein the first polymer comprises poly(trimethylene terephthalate) and the weight ratio of the poly(trimethylene terephthalate) to the second polymer is in the range of from about 80:20 to about 10:90; or the the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of about 90:10 to about 10:90. The spun yarn may further comprise a second staple fiber such as cotton or wool. The spun yarn is useful in preparing fabrics having advantageous properties.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. provisional application No. 62/691066, titled “Fabrics and Spun Yarns Comprising Polyester Staple Fiber,” filed Jun. 28, 2018, and U.S. provisional application No. 62/747999, also titled “Fabrics and Spun Yarns Comprising Polyester Staple Fiber,” filed Oct. 19, 2018 the disclosure of both of which is incorporated by reference herein in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure is directed towards spun yarn comprising melt spun staple fiber comprising a first polymer and a second polymer, and to fabrics comprising the spun yarn. The first polymer comprises poly(trimethylene terephthalate) or poly(butylene terephthalate), and the second polymer comprises poly(ethylene terephthalate) or Co-PET, wherein Co-PET is a poly(ethylene terephthalate) copolymer comprising isophthalic acid monomer.

BACKGROUND

Poly(trimethylene terephthalate) (PTT) is a commercial fiber, offering desirable properties such as easy disperse dyeability at atmospheric pressure, relatively low bending modulus, and relatively high elastic recovery and resilience. Processes for the production of PTT staple fibers are known, however consistent processing of PTT into staple is often hampered by the shrinkage of partially oriented tow during storage prior to drawing, crimping, and cutting. Shrinkage is affected by storage time and storage temperature, and uncontrolled shrinkage leads to denier nonuniformity and draw breaks during the drawing process. As a result, commercialization of PTT staple or blends of PTT staple with natural fibers has been limited.

In certain textile end uses, staple fibers are preferred over continuous filament. For example, staple spun yarns for apparel fabrics require discontinuous fiber rather than continuous to permit use of textile staple processing equipment. Staple fibers additionally allow blending synthetic fibers with natural fibers, such as wool, cotton, and cellulose. The manufacture of staple fiber suitable for fabrics can present special problems, particularly in conventional split spin/draw processes where the drawing is carried out in a separate step and characteristics of the undrawn fiber, for example dry heat shrinkage, can change as the undrawn fiber ages during storage.

There is a continuing need for PTT-based staple of good uniformity and tenacity, and economical processes to produce such staple. There is a continuing need for spun yarns comprising PTT-based staple fiber and having good tenacity and elongation at break, and which can impart desired qualities to fabrics comprising such spun yarns.

SUMMARY

Disclosed herein are melt spun staple fibers, spun yarns comprising the melt spun staple fibers, and fabrics comprising the spun yarns. In one embodiment, a spun yarn is disclosed, the spun yarn comprising melt spun staple fiber comprising a first polymer comprising poly(trimethylene terephthalate) or poly(butylene terephthalate) and a second polymer comprising poly(ethylene terephthalate) or Co-PET, wherein Co-PET is a poly(ethylene terephthalate) copolymer comprising isophthalic acid monomer; and wherein the first polymer comprises poly(trimethylene terephthalate) and the weight ratio of the poly(trimethylene terephthalate) to the second polymer is in the range of from about 80:20 to about 10:90; or the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of from about 90:10 to about 10:90. In another embodiment of the spun yarn, the weight ratio of the poly(trimethylene terephthalate) or the poly(butylene terephthalate) to the second polymer is in the range of from about 70:30 to 30:70. In a further embodiment, the spun yarn has a boil off shrinkage of at least about 6% as determined according to ASTM D2259.

In one embodiment of the spun yarn, the melt spun staple fiber comprises poly(trimethylene terephthalate) and poly(ethylene terephthalate). In another embodiment of the spun yarn, the melt spun staple fiber comprises poly(trimethylene terephthalate) and Co-PET. In one embodiment of the spun yarn, the first polymer comprises poly(trimethylene terephthalate) and the second polymer comprises Co-PET, and the co-PET contains from about 0.5 mole percent to about 10 mole percent isophthalic acid monomer, based on the total copolymer composition. In an additional embodiment of the spun yarn, the melt spun staple fiber comprises poly(butylene terephthalate) and poly(ethylene terephthalate). In yet another embodiment of the spun yarn, the melt spun staple fiber comprises poly(butylene terephthalate) and Co-PET. In one embodiment of the spun yarn, the first polymer comprises poly(butylene terephthalate) and the second polymer comprises Co-PET, and the Co-PET contains from about 0.5 mole percent to about 10 mole percent isophthalic acid monomer, based on the total copolymer composition. In a further embodiment of the spun yarn, the second polymer comprises Co-PET, and the Co-PET contains from about 0.5 mole percent to about 10 mole percent isophthalic acid monomer, based on the total copolymer composition.

In one embodiment, the spun yarn further comprises a second staple fiber in an amount from about 5 wt % to about 95 wt %, based on the total weight of the spun yarn. In an additional embodiment, the second staple fiber comprises polylactic acid, acrylic, nylon, olefin, acetate, rayon, or polyester. In a further embodiment, the second staple fiber comprises at least one natural fiber selected from cotton, linen, wool, angora, mohair, alpaca, or cashmere. In another embodiment, the second staple fiber comprises polylactic acid, acrylic, nylon, olefin, acetate, rayon, polyester, cotton, linen, wool, angora, mohair, alpaca, cashmere, or a mixture thereof. In yet another embodiment, the second staple fiber comprises cotton or wool.

In one embodiment, the second staple fiber comprises cotton. In one embodiment, the spun yarn further comprises a second staple fiber comprising cotton, and the cotton is present in an amount from about 5 wt % to about 95 wt %, based on the total weight of the spun yarn. In another embodiment, the spun yarn further comprising cotton has a cotton count of about 4 Ne to about 80 Ne.

In another embodiment, the second staple fiber comprises wool. In one embodiment, the spun yarn further comprises a second staple fiber comprising wool, and the wool is present in an amount from about 5 wt % to about 95 wt %, based on the total weight of the spun yarn. In another embodiment, the spun yarn further comprising wool has a worsted count in the range of from 7 Nm to 120 Nm.

In another embodiment, a fabric is disclosed, the fabric comprising a spun yarn as disclosed herein. In one embodiment, the fabric has a softer hand and better drape than a fabric of the same fabric construction consisting of rayon, polyethylene terephthalate, cotton, or a combination thereof. In one embodiment, the fabric has at least one of: i) better abrasion resistance as determined according to ASTM D4966 Standard Test Method; ii) higher pill rating values as determined according to ASTM D4970 Standard Test Method,; or iii) greater bulk as determined according to ASTM D1777 Standard Test Method; than a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. In another embodiment, the fabric has better dyeability than a fabric of the same construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. In yet another embodiment, the fabric has better abrasion resistance than a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. In a further embodiment, the fabric has less pilling (higher pill rating values) than a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. In an additional embodiment, the fabric has greater bulk than a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.

In one embodiment, the fabric is a woven fabric having a warp and a weft. In one embodiment, the fabric is a woven fabric having a warp and a weft, and the warp, the weft, or both the warp and the weft each comprise a spun yarn as disclosed herein. In an additional embodiment, the warp comprises a spun yarn as disclosed herein. In another embodiment, the weft comprises a spun yarn as disclosed herein. In yet a further embodiment, the warp and the weft each comprise a spun yarn as disclosed herein. In another embodiment, the fabric is a knit fabric. In one embodiment, the knit fabric has higher recovery than a knit fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. Also disclosed herein are articles comprising a fabric as disclosed herein, for example a garment.

In yet another embodiment, melt spun staple fiber is disclosed, the fiber comprising a first polymer comprising poly(trimethylene terephthalate) or poly(butylene terephthalate) and a second polymer comprising poly(ethylene terephthalate) or Co-PET, wherein Co-PET is a poly(ethylene terephthalate) copolymer comprising isophthalic acid monomer, the staple fiber having a weight ratio of the first polymer to the second polymer in the range of about 70:30 to about 30:70, and a dry heat shrinkage of less than 6% as determined by the Dry Heat Shrinkage Method. In one embodiment, the melt spun staple fiber comprises poly(trimethylene terephthalate) and poly(ethylene terephthalate). In another embodiment, the melt spun staple fiber comprises poly(trimethylene terephthalate) and Co-PET. In an additional embodiment, the melt spun staple fiber comprises poly(butylene terephthalate) and poly(ethylene terephthalate). In yet another embodiment, the melt spun staple fiber comprises poly(butylene terephthalate) and Co-PET In a further embodiment, the second polymer comprises Co-PET, and the Co-PET contains from about 0.5 mole percent to about 10 mole percent isophthalic acid monomer, based on the total copolymer composition. In yet another embodiment of the melt spun staple fiber, the weight ratio of the first polymer to the second polymer is in the range of from about 70:30 to 50:50.

DETAILED DESCRIPTION

All patents, patent applications, and publications cited herein are incorporated herein by reference in their entirety.

As used herein, the term “embodiment” or “disclosure” is not meant to be limiting, but applies generally to any of the embodiments defined in the claims or described herein. These terms are used interchangeably herein.

In this disclosure, a number of terms and abbreviations are used. The following definitions apply unless specifically stated otherwise.

The articles “a”, “an”, and “the” preceding an element or component are intended to be nonrestrictive regarding the number of instances (i.e. occurrences) of the element or component. There “a”, “an”, and “the” should be read to include one or at least one, and the singular word form of the element or component also includes the plural unless the number is obviously meant to be singular.

The term “comprising” means the presence of the stated features, integers, steps, or components as referred to in the claims, but that it does not preclude the presence or addition of one or more other features, integers, steps, components, or groups thereof. The term “comprising” is intended to include embodiments encompassed by the terms “consisting essentially of” and “consisting of”. Similarly, the term “consisting essentially of” is intended to include embodiments encompassed by the term “consisting of”.

Where present, all ranges are inclusive and combinable. For example, when a range of “1 to 5” is recited, the recited range should be construed as including ranges “1 to 4”, “1 to 3”, 1-2”, “1-2 and 4-5”, “1-3 and 5”, and the like.

As used herein in connection with a numerical value, the term “about” refers to a range of +/−0.5 of the numerical value, unless the term is otherwise specifically defined in context. For instance, the phrase a “pH value of about 6” refers to pH values of from 5.5 to 6.5, unless the pH value is specifically defined otherwise.

It is intended that every maximum numerical limitation given throughout this Specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this Specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this Specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.

The features and advantages of the present disclosure will be more readily understood, by those of ordinary skill in the art from reading the following detailed description. It is to be appreciated that certain features of the disclosure, which are, for clarity, described above and below in the context of separate embodiments, may also be provided in combination in a single element. Conversely, various features of the disclosure that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination.

The use of numerical values in the various ranges specified in this application, unless expressly indicated otherwise, are stated as approximations as though the minimum and maximum values within the stated ranges were both proceeded by the word “about”. In this manner, slight variations above and below the stated ranges can be used to achieve substantially the same results as values within the ranges. Also, the disclosure of these ranges is intended as a continuous range including each and every value between the minimum and maximum values.

As used herein:

By “poly(trimethylene terephthalate)” or PTT is meant polymer comprising repeat units derived from 1,3-propanediol and terephthalic acid (or equivalent). As used herein, the term “poly(trimethylene terephthalate) homopolymer” means polymer of substantially only 1,3-propanediol and terephthalic acid (or equivalent). As used herein, the term “poly(trimethylene terephthalate)” also includes PTT copolymers, by which is meant polymer comprising repeat units derived from 1,3-propanediol and terephthalic acid (or equivalent) and also containing at least one additional unit derived from an additional monomer. Examples of PTT copolymers include copolyesters made using 3 or more reactants, each having two ester forming groups. For example, a copoly(trimethylene terephthalate) can be used in which the comonomer used to make the copolyester is selected from the group consisting of linear, cyclic, and branched aliphatic dicarboxylic acids having 4-12 carbon atoms (for example butanedioic acid, pentanedioic acid, hexanedioic acid, dodecanedioic acid, and 1,4-cyclo-hexanedicarboxylic acid); aromatic dicarboxylic acids other than terephthalic acid and having 8-12 carbon atoms (for example isophthalic acid and 2,6-naphthalenedicarboxylic acid); linear, cyclic, and branched aliphatic diols having 2-8 carbon atoms (other than 1,3-propanediol, for example, ethanediol, 1,2-propanediol, 1,4-butanediol, 3-methyl-1,5-pentanediol, 2,2-dimethyl-1,3-propanediol, 2-methyl-1,3-propanediol, and 1,4-cyclohexanediol); and aliphatic and aromatic ether glycols having 4-10 carbon atoms (for example, hydroquinone bis(2-hydroxyethyl) ether, or a poly(ethylene ether) glycol having a molecular weight below about 460, including diethylene ether glycol). The comonomer typically is present in the copolyester at a level in the range of about 0.5 mole % to about 15 mole %, and can be present in amounts up to about 30 mole %.

As used herein, the term “poly(butylene terephthalate)” or PBT means polymer derived from substantially only 1,4-butanediol and terephthalic acid, and is also referred to as poly(butylene terephthalate) homopolymer. As used herein, the term “poly(butylene terephthalate) copolymer refers to polymer comprising repeat units derived from 1,4-butanediol and terephthalic acid and also containing at least one additional unit derived from an additional monomer, for example a comonomer for PTT copolymers as disclosed herein.

As used herein, the term “poly(ethylene terephthalate)” or PET means polymer derived from substantially only ethylene glycol and terephthalic acid (or equivalent, such as dimethyl terephthalate), and is also referred to as poly(ethylene terephthalate) homopolymer. As used herein, the term “poly(ethylene terephthalate) copolymer” refers to polymer comprising repeat units derived from ethylene glycol and terephthalic acid (or equivalent) and also containing at least one additional unit derived from an additional monomer.

As used herein, the term “Co-PET” refers to poly(ethylene terephthalate) copolymers in which the additional monomer is isophthalic acid (or an ester equivalent). As such, Co-PET is a poly(ethylene terephthalate) copolymer comprising ethylene terephthalate and isophthalic acid monomers.

“Staple” refers to either natural fibers or cut lengths from filaments. The term staple (fiber) is used in the textile industry to distinguish natural or cut man-made fibers from filament. Man-made fibers are cut to a specific length, for example, as long as 8 inches or as short as 1.5 inches or less, so they can be processed on cotton, woolen, or worsted yarn spinning systems, or flocked.

The term “melt spun staple fiber” refers to staple fiber obtained by melting a fiber-forming substance, extruding it through a spinneret, then solidifying it directly by cooling; such melt spun fiber is stored, combined with other batches of melt spun fiber obtained similarly, and collectively drawn, crimped, heat treated for stabilization, and cut to obtain staple fiber.

The term “spun yarn” refers to yarn produced by aligning cut staple fibers in multiple steps wherein a tow of cut staple fibers is successively drafted into a lower and lower denier continuous strand and in which the staple fibers are bound together by twist.

“Undrawn yarn” is a term customarily applied to fiber that has not been drawn, and is not intended herein to include fibers that have been drawn and processed into a yarn product, such as those yarns used in knitting or weaving fabric. After melt spinning, undrawn yarn is accumulated until an appropriate total denier for the draw machine is produced. Accumulation can take up to 24 hours or more including dormant or storage time between steps. For example, making sufficient undrawn yarn for economic drawing at the draw line generally takes 6 hours or more. Due to production scheduling and other practical considerations, fiber may be stored for several days. Fiber having been exposed to such storage time is referred to as “aged” or “aged undrawn yarn”.

“Draw ratio”, or “draw down”, is the amount by which filaments are stretched following melt spinning. As used herein, “draw ratio” refers to machine draw ratio, which is the ratio of the surface speed of the pulling rolls to the forwarding rolls (rolls that move the fiber). As a result of pulling, some stretching occurs.

“Carding” is a process whereby staple fiber bunch is opened, individualized, aligned and formed into a continuous untwisted strand called sliver. The card machine consists of a series of rolls whose surfaces are covered with many projecting metal teeth or pins.

“Tow” means a large strand of continuous manufactured fiber filaments without definite twist, collected in loose, rope-like form before being cut into staple or formed into sliver.

A “sliver” is a continuous strand of loosely assembled staple fibers without twist. Sliver is delivered by the card or drawing frame. The production of sliver is the first step in the textile operation that converts staple fiber into a form that can be drawn and eventually twisted into a spun yarn.

The term “fabric” means a planar textile structure produced by interlacing yarns, fibers, or filaments.

The term “woven fabric” means a fabric composed of warp yarns and filling (weft) yarns which are interlaced. In a weaving process, the lengthwise or longitudinal warp yarns are held stationary in tension on a frame or loom while the transverse weft (which can also be referred to as woof) is drawn through and inserted over-and-under the warp.

The term “knit fabric” means a fabric produced by interlooping one or more ends of yarn.

The term “fabric construction” means the details of the structure of a fabric, including the style, width, type of weave or knit, number of yarns per inch in the warp and weft, and the weight of goods.

The term “decitex” (dtex) is a unit of measure for the linear mass density of fiber or yarn, and is defined as the mass in grams per 10,000 meters.

The term “sliver linear density” means the weight in grams of a one meter length of sliver.

The term “sliver linear density” (after the carding step) means the number of 840 yards cut length of sliver in one pound weight, expressed in English count Ne, or weight of sliver in grams in 1000 meter length expressed as g/meter.

The term “final sliver linear density” (after drawing step) means the number of 840 yards cut length of sliver in one pound weight expressed in English count Ne, or weight of sliver in grams in one meter expressed as g/meter.

The term “unevenness %” means the average mean deviation in weight of a 400 meter length of spun yarn, or in a 50 meter length of roving or a 50 meter length of sliver, as measured by Uster evenness tester-3 (UT3), expressed as a percentage. Measured by industrial established method using UT-3 and 400 m length of yarn or 25 m or 50 m length of sliver or roving.

The term “imperfections” with regard to spun yarn means the numerical sum of the number of thick regions, the number of thin regions, and the number of neps in a 1000 meter length of yarn, as determined using a Uster evenness tester. As used herein, the term “thick region” means a place on the spun yarn having mass greater than or equal to +150% of the average mass of the yarn in a 8 mm cut length. As used herein, the term “thin region” means a place on the spun yarn having mass less than or equal to 50% of average mass of the yarn in a 8 mm cut length. As used herein, the term “neps” means a place on the spun yarn having mass greater than or equal to 200% of the average mass of the yarn in a 1 mm cut length.

The term “hairiness index” refers to the average of total length of protruding fiber per 1 cm length of yarn measured in 400 m length of yarn, measured optically using a UT3 tester, expressed as normalized units.

The present disclosure is directed to spun yarn comprising melt spun staple fiber comprising a first polymer comprising poly(trimethylene terephthalate) or poly(butylene terephthalate) and a second polymer comprising poly(ethylene terephthalate) or Co-PET, wherein Co-PET is a poly(ethylene terephthalate) copolymer comprising isophthalic acid monomer; and wherein the first polymer comprises poly(trimethylene terephthalate) and the weight ratio of the poly(trimethylene terephthalate) to the second polymer is in the range of about 80:20 to about 10:90; or the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of from about 90:10 to about 10:90. The melt spun staple fiber lacks any distinct interface between the first and second polymers. The spun yarn has a boil off shrinkage of at least about 6%, as determined according to ASTM D2259. Optionally, the spun yarn can comprise a second staple fiber, for example cotton or wool. Fabrics with desirable characteristics can be made from the spun yarns.

It has been found that the melt spun staple fiber disclosed herein has improved tenacity, crimp, and stability in comparison to PTT melt spun staple fiber, and the properties of the melt spun staple fiber advantageously enable processing under conditions typically used with PET during staple conversion into spun yarns. Additionally, the spun yarns comprising the melt spun staple fiber disclosed herein, whether further comprising a second staple fiber or consisting essentially of the melt spun staple fiber alone, enable production of woven, knitted, and nonwoven fabrics having cotton-like aesthetics, good strength, and other desirable attributes.

In one embodiment, the melt spun staple fiber of the spun yarn comprises a first polymer comprising poly(trimethylene terephthalate). Poly(trimethylene terephthalate) suitable for use in the melt spun staple fiber is well known in the art and can be prepared, for example, by polycondensation of 1,3-propane diol with terephthalic acid or terephthalic acid equivalent. Optionally, the 1,3-propane diol may be obtained biochemically from a renewable source (“biologically-derived” 1,3-propanediol). Poly(trimethylene terephthalate)s are commercially available from E. I. du Pont de Nemours and Company, Wilmington, Del. under the trademark Sorona®. Optionally, PTT or its monomers could be obtained from recycling post-industrial or post-consumer materials (i.e. fiber or plastic waste).

By “terephthalic acid equivalent” is meant compounds that perform substantially like terephthalic acids in reaction with polymeric glycols and diols, as would be generally recognized by a person of ordinary skill in the relevant art. Terephthalic acid equivalents include, for example, esters (such as dimethyl terephthalate), and ester-forming derivatives such as acid halides (e.g., acid chlorides) and anhydrides. Terephthalic acid and terephthalic acid esters, for example the dimethyl ester, are suitable. Methods for preparation of poly(trimethylene terephthalate) are disclosed, for example, in U.S. Pat. Nos. 6,277,947, 6,326,456, 6,657,044, 6,353,062, 6,538,076, and 7,531,617.

Preferably the 1,3-propanediol used as a reactant or as a component of the reactant in making poly(trimethylene terephthalate) has a purity of greater than about 99%, for example greater than about 99.9%, by weight as determined by gas chromatographic analysis. Purified 1,3-propanediols are disclosed in U.S. Pat. No. 7,038,092, 7,098,368, 7,084,311, and 7,919,658.

Poly(trimethylene terephthalate) suitable for use in the melt spun fibers can be poly(trimethylene terephthalate) homopolymers (derived substantially from 1,3-propane diol and terephthalic acid and/or equivalent) and copolymers. In one embodiment, the poly(trimethylene terephthalate) contains about 70 mole % or more of repeat units derived from 1,3-propane diol and terephthalic acid (and/or an equivalent thereof, such as dimethyl terephthalate). The poly(trimethylene terephthalate) can contain at least about 85 mole %, or at least about 90 mole %, or at least about 95 mole %, or at least about 99 mole %, or about 100 mole % of repeat units derived from 1,3-propane diol and terephthalic acid (or equivalent).

The poly(trimethylene terephthalate) can contain minor amounts of other comonomers, and such comonomers are usually selected so that they do not have a significant adverse effect on properties. Such other comonomers include 5-sodium-sulfoisophthalate, for example, at a level in the range of about 0.2 to 5 mole %. Very small amounts of trifunctional comonomers, for example trimellitic acid, can be incorporated for viscosity control.

The poly(trimethylene terephthalate) can contain up to 30 mole % of repeat units made from other diols or diacids. Other diacids include, for example, isophthalic acid, 1,4-cyclohexane dicarboxylic acid, 2,6-naphthalene dicarboxylic acid, 1,3-cyclohexane dicarboxylic acid, succinic acid, glutaric acid, adipic acid, sebacic acid, 1,12-dodecane dioic acid, and the derivatives thereof such as the dimethyl, diethyl, or dipropyl esters of these dicarboxylic acids. Other diols include ethylene glycol, 1,4-butane diol, 1,2-propanediol, diethylene glycol, triethylene glycol, 1,3-butane diol, 1,5-pentane diol, 1,6-hexane diol, 1,2-, 1,3- and 1,4-cyclohexane dimethanol, and the longer chain diols and polyols made by the reaction product of diols or polyols with alkylene oxides.

The poly(trimethylene terephthalate) can also include functional monomers, for example, up to about 5 mole % of sulfonate compounds useful for imparting cationic dyeability. Specific examples of preferred sulfonate compounds include 5-lithium sulfoisophthalate, 5-sodium sulfoisophthalate, 5-potassium sulfoisophthalate, 4-sodium sulfo-2,6-naphthalenedicarboxylate, tetramethylphosphonium 3,5-dicarboxybenzene sulfonate, tetrabutylphosphonium 3,5-dicarboxybenzene sulfonate, tributyl-methylphosphonium 3,5-dicarboxybenzene sulfonate, tetrabutylphosphonium 2,6-dicarboxynaphthalene-4-sulfonate, tetramethylphosphonium 2,6-dicarboxynapthalene-4-sulfonate, ammonium 3,5-dicarboxybenzene sulfonate, and ester derivatives thereof, for example methyl or dimethyl esters.

Poly(trimethylene terephthalate) has an intrinsic viscosity that typically is about 0.5 deciliters/gram (dl/g) or higher, and typically is about 2 dl/g or less. In one embodiment, the poly(trimethylene terephthalate) has an intrinsic viscosity that is about 0.7 dl/g or higher, for example 0.8 dl/g or higher, or for example 0.9 dl/g or higher, and typically it is about 1.5 dl/g or less, for example 1.4 dl/g or less, and commercial products presently available have intrinsic viscosities of 1.2 dl/g or less.

In another embodiment, the melt spun staple fiber of the spun yarn comprises a first polymer comprising poly(butylene terephthalate). Poly(butylene terephthalate) suitable for use in the melt spun staple fiber is also well known in the art and can be prepared, for example, by polycondensation of 1,4-butanediol with terephthalic acid. Poly(butylene terephthalate)s are commercially available from E. I. du Pont de Nemours and Company, Wilmington, Del. under the trademark Crastin®.

Poly(butylene terephthalate) suitable for use in the melt spun fibers can be homopolymers (derived substantially from 1,4-butanediol and terephthalic acid and/or equivalent) and copolymers. In one embodiment, the poly(butylene terephthalate) contains about 80 mole % or more of repeat units derived from 1,4-butanediol and terephthalic acid. In other embodiment, the poly(butylene terephthalate) can contain at least about 85 mole %, or at least about 90 mole %, or at least about 95 mole %, or at least about 99 mole %, or about 100 mole % of repeat units derived from 1,4-butanediol and terephthalic acid (or equivalent). The poly(trimethylene terephthalate) can contain minor amounts of other comonomers or functional monomers. Optionally, PBT or its monomers could be obtained from recycling post-industrial or post-consumer materials (i.e. fiber or plastic waste).

Polyethylene terephthalate (PET) is a polyester that may be prepared by the condensation polymerization of ethylene glycol and terephthalic acid (or dimethyl terephthalate or other terephthalate ester). Processes for producing poly(ethylene terephthalate) are known, for example as disclosed in U.S. Pat. No. 3,398,124 and U.S. Pat. No. 3,487,049. Poly(ethylene terephthalate) suitable for use in preparing the melt spun staple fiber disclosed herein is also commercially available. In one embodiment, the poly(ethylene terephthalate) is a homopolymer and is derived substantially from ethylene glycol and terephthalic acid and/or equivalent. Optionally, PET or its monomers could be obtained from recycling post-industrial or post-consumer material (i.e. fiber or plastic waste).

In many applications, it can be desirable to modify the properties of poly(ethylene terephthalate) by adding a third monomer. For example, a copolymer of polyethylene terephthalate can be prepared from monomers of dimethyl terephthalate or terephthalic acid in combination with cyclohexane dimethanol, or in combination with cyclohexane dimethanol and ethylene glycol. In other cases, isophthalic acid can be used to replace a portion of the terephthalic acid monomer, which disrupts crystallinity and lowers the melting point of the copolymer, which is referred to herein as “Co-PET”.

As used herein, “Co-PET” refers to poly(ethylene terephthalate) copolymers that may be prepared by the condensation polymerization of ethylene glycol, terephthalic acid (or dimethyl terephthalate or other terephthalate ester) and isophthalic acid (or dimethyl isophthalate or other terephthalate ester), as known in the art. Co-PET can also be produced in a process in which recycled poly(ethylene terephthalate) bottles are chopped, melted, purified, and repelletized to produce fiber-grade post-consumer recycled Co-PET. The isophthalic acid monomer is typically present in Co-PET at a level in the range of about 0.5 mole % to about 15 mole %, and can be present in amounts up to about 30 mole %, based on the total copolymer composition. For example, Co-PET can contain about 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 mole %, of isophthalic acid monomer. In one embodiment, Co-PET useful in the melt spun staple fibers disclosed herein contains from about 1 mole % to about 5 mole %, or up to about 10 mole %, or up to about 15 mole %, isophthalic acid monomer, based on the total copolymer composition. In another embodiment, useful Co-PET contains from about 0.5 mol % to about 3 mole % isophthalic acid monomer. The amount of isophthalic acid monomer in Co-PET can be selected to provide the desired properties to the Co-PET. It is thought that the lower melting point of Co-PET can improve the compatibility of Co-PET and poly(trimethylene terephthalate) during melt spinning. Co-PET is commercially available.

In some embodiments, a polyethylene terephthalate copolymer containing an additional monomer other than isophthalic acid may be used. For example, a polyethylene terephthalate copolymer comprising ethylene glycol, terephthalic acid (or equivalent), and a dicarboxylic acid such as succinic acid, adipic acid, azelaic acid, sebacic acid, glutaric acid, 1,10-decanedicarboxylic acid, phthalic acid, dodecanedioic acid, sulfonated isophthalic acid, oxalic acid, fumaric acid, maleic acid, itaconic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanedicarboxylic acid, and mixtures there of may be useful in preparing a melt spun staple fiber. Alternatively, a polyethylene terephthalate copolymer comprising ethylene glycol, terephthalic acid (or equivalent), and a diol such as diethylene glycol, polyethylene glycol, butylene glycol, 1,4-cyclohexane dimethanol, 1,2-cyclohexanediol, 1,4-cyclohexanediol, 1,3-cyclohexanediol, 1,5-pentanediol, 1,6-hexanediol, and mixtures thereof may be useful in preparing a melt spun staple fiber.

In one embodiment, Co-PET is a poly(ethylene terephthalate) copolymer comprising ethylene terephthalate and isophthalic acid monomers. In another embodiment, Co-PET is a poly(ethylene terephthalate) copolymer consisting essentially of poly(ethylene terephthalate) and isophthalic acid monomers. In a further embodiment, Co-PET is a poly(ethylene terephthalate) copolymer consisting of poly(ethylene terephthalate) and isophthalic acid monomers.

The melt spun staple fiber comprises a first polymer comprising poly(trimethylene terephthalate) or poly(butylene terephthalate) and a second polymer comprising poly(ethylene terephthalate) or Co-PET; and wherein the first polymer comprises poly(trimethylene terephthalate) and the weight ratio of the poly(trimethylene terephthalate) to the second polymer is in the range of about 80:20 to about 10:90; or the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of from about 90:10 to about 10:90. In one embodiment, the melt spun staple fiber comprises poly(trimethylene terephthalate) (PTT) and poly(ethylene terephthalate) (PET), and the melt spun staple fiber comprises about 80 weight percent PTT and about 20 weight percent PET. In one embodiment, the melt spun staple fiber comprises about 75 weight percent PTT and about 25 weight percent PET. In one embodiment, the melt spun staple fiber comprises about 70 weight percent PTT and about 30 weight percent PET. In another embodiment, the staple fiber comprises about 65 weight percent PTT and about 35 weight percent PET. In yet another embodiment, the staple fiber comprises about 60 weight percent PTT and about 40 weight percent PET. In an additional embodiment, the staple fiber comprises about 55 weight percent PTT and about 45 weight percent PET. In a further embodiment, the staple fiber comprises about 50 weight percent PTT and about 50 weight percent PET. In another embodiment, the staple fiber comprises about 45 weight percent PTT and about 55 weight percent PET. In a separate embodiment, the staple fiber comprises about 40 weight percent PTT and about 60 weight percent PET. In another embodiment, the staple fiber comprises about 35 weight percent PTT and about 65 weight percent PET. In yet another embodiment, the staple fiber comprises about 30 weight percent PTT and about 70 weight percent PET. In one embodiment, the melt spun staple fiber comprises about 25 weight percent PTT and about 75 weight percent PET. In one embodiment, the melt spun staple fiber comprises about 20 weight percent PTT and about 80 weight percent PET. In one embodiment, the melt spun staple fiber comprises about 15 weight percent PTT and about 85 weight percent PET. In one embodiment, the melt spun staple fiber comprises about 10 weight percent PTT and about 90 weight percent PET.

In one embodiment, the melt spun staple fiber comprises poly(trimethylene terephthalate (PTT) and a poly(ethylene terephthalate) copolymer comprising isophthalic acid monomer (Co-PET), and the weight ratio of PTT to Co-PET is in the range of about 80:20 to about 10:90. In one embodiment, the melt spun staple fiber comprises about 80 weight percent PTT and about 20 weight percent Co-PET. In an additional embodiment, the melt spun staple fiber comprises about 75 weight percent PTT and about 25 weight percent Co-PET. In one embodiment, the melt spun staple fiber comprises about 70 weight percent PTT and about 30 weight percent Co-PET. In another embodiment, the melt spun staple fiber comprises about 65 weight percent PTT and about 35 weight percent Co-PET. In yet another embodiment, the melt spun staple fiber comprises about 60 weight percent PTT and about 40 weight percent Co-PET. In an additional embodiment, the melt spun staple fiber comprises about 55 weight percent PTT and about 45 weight percent Co-PET. In a further embodiment, the melt spun staple fiber comprises about 50 weight percent PTT and about 50 weight percent Co-PET. In another embodiment, the melt spun staple fiber comprises about 45 weight percent PTT and about 55 weight percent Co-PET. In a separate embodiment, the melt spun staple fiber comprises about 40 weight percent PTT and about 60 weight percent Co-PET. In another embodiment, the melt spun staple fiber comprises about 35 weight percent PTT and about 65 weight percent Co-PET. In yet another embodiment, the melt spun staple fiber comprises about 30 weight percent PTT and about 70 weight percent Co-PET. In one embodiment, the melt spun staple fiber comprises about 25 weight percent PTT and about 75 weight percent Co-PET. In another embodiment, the melt spun staple fiber comprises about 20 weight percent PTT and about 80 weight percent Co-PET. In yet another embodiment, the melt spun staple fiber comprises about 15 weight percent PTT and about 85 weight percent Co-PET. In an additional embodiment, the melt spun staple fiber comprises about 10 weight percent PTT and about 90 weight percent Co-PET.

In one embodiment, the melt spun staple fiber comprises poly(butylene terephthalate) (PBT) and poly(ethylene terephthalate) (PET), and the melt spun staple fiber comprises about 90 weight percent PBT and about 10 weight percent PET. In another embodiment, the melt spun staple fiber comprises about 85 weight percent PBT and about 15 weight percent PET. In one embodiment, the melt spun staple fiber comprises about 80 weight percent PBT and about 20 weight percent PET. In one embodiment, the melt spun staple fiber comprises about 75 weight percent PBT and about 25 weight percent PET. In one embodiment, the melt spun staple fiber comprises about 70 weight percent PBT and about 30 weight percent PET. In another embodiment, the staple fiber comprises about 65 weight percent PBT and about 35 weight percent PET. In yet another embodiment, the staple fiber comprises about 60 weight percent PBT and about 40 weight percent PET. In an additional embodiment, the staple fiber comprises about 55 weight percent PBT and about 45 weight percent PET. In a further embodiment, the staple fiber comprises about 50 weight percent PBT and about 50 weight percent PET. In another embodiment, the staple fiber comprises about 45 weight percent PBT and about 55 weight percent PET. In a separate embodiment, the staple fiber comprises about 40 weight percent PBT and about 60 weight percent PET. In another embodiment, the staple fiber comprises about 35 weight percent PBT and about 65 weight percent PET. In yet another embodiment, the staple fiber comprises about 30 weight percent PBT and about 70 weight percent PET. In one embodiment, the melt spun staple fiber comprises about 25 weight percent PBT and about 75 weight percent PET. In one embodiment, the melt spun staple fiber comprises about 20 weight percent PBT and about 80 weight percent PET. In one embodiment, the melt spun staple fiber comprises about 15 weight percent PBT and about 85 weight percent PET. In one embodiment, the melt spun staple fiber comprises about 10 weight percent PBT and about 90 weight percent PET.

In one embodiment, the melt spun staple fiber comprises poly(butylene terephthalate (PBT) and a poly(ethylene terephthalate) copolymer comprising isophthalic acid monomer (Co-PET), and the weight ratio of PBT to Co-PET is in the range of about 90:10 to about 10:90. In one embodiment, the melt spun staple fiber comprises about 85 weight percent PBT and about 15 weight percent Co-PET. In another embodiment, the melt spun staple fiber comprises about 80 weight percent PBT and about 20 weight percent Co-PET. In an additional embodiment, the melt spun staple fiber comprises about 75 weight percent PBT and about 25 weight percent Co-PET. In one embodiment, the melt spun staple fiber comprises about 70 weight percent PBT and about 30 weight percent Co-PET. In another embodiment, the melt spun staple fiber comprises about 65 weight percent PBT and about 35 weight percent Co-PET. In yet another embodiment, the melt spun staple fiber comprises about 60 weight percent PBT and about 40 weight percent Co-PET. In an additional embodiment, the melt spun staple fiber comprises about 55 weight percent PBT and about 45 weight percent Co-PET. In a further embodiment, the melt spun staple fiber comprises about 50 weight percent PBT and about 50 weight percent Co-PET. In another embodiment, the melt spun staple fiber comprises about 45 weight percent PBT and about 55 weight percent Co-PET. In a separate embodiment, the melt spun staple fiber comprises about 40 weight percent PBT and about 60 weight percent Co-PET. In another embodiment, the melt spun staple fiber comprises about 35 weight percent PBT and about 65 weight percent Co-PET. In yet another embodiment, the melt spun staple fiber comprises about 30 weight percent PBT and about 70 weight percent Co-PET. In one embodiment, the melt spun staple fiber comprises about 25 weight percent PBT and about 75 weight percent Co-PET. In another embodiment, the melt spun staple fiber comprises about 20 weight percent PBT and about 80 weight percent Co-PET. In yet another embodiment, the melt spun staple fiber comprises about 15 weight percent PBT and about 85 weight percent Co-PET. In an additional embodiment, the melt spun staple fiber comprises about 10 weight percent PBT and about 90 weight percent Co-PET.

The melt spun staple fiber can be formed in a two-stage process. In the first stage, the polymers are combined, melted, extruded to form filaments comprising the polymers, the filaments are cooled, and collected as tow. In the second stage, the tow can be processed through at least one stage of draw, crimped, annealed, and cut to produce staple fiber. Processes to prepare polyester staple fiber are known, for example as disclosed in U.S. Pat. No. 5,308,564.

The first polymer (PTT or PBT) and the second polymer (PET or Co-PET), can be combined by any known technique. The polymers can be combined in a variety of ways, for example they can be (a) heated and mixed simultaneously, (b) pre-mixed in a separate apparatus before heating, or (c) heated and then mixed. The mixing, heating, and forming can be carried out by conventional equipment designed for that purpose such as extruders. The temperature should be above the melting points of each polymer but below the lowest decomposition temperature. Suitable temperatures can be in the range of about 140° C. to about 240° C., for example at least about 200° C. and up to about 230° C. In one embodiment, the melt temperature is below 280° C.

In one embodiment, the polymers can be compounded, for example in a compounding screw, in a desired ratio to form pellets which are then fed to a spinning machine extruder. In another embodiment, pellets can be made of each polymer separately, and then the pellets are blended together as a salt-and-pepper mixture using up to two feeders to a spinning machine extruder. Alternatively, pellets can be made of each polymer separately, and the pellets pre-mixed together before being fed to a spinning machine extruder. In yet another embodiment, each polymer can be melted to form a molten polymer stream, and then the molten polymer streams can be combined, and pellets formed from the molten mixture. The term “pellets” is used generically herein, and is used regardless of shape so that it includes products sometimes called “chips” or “flakes”.

If desired, additives can be added to the poly(trimethylene terephthalate), to the poly(butylene terephthalate), to the poly(ethylene terephthalate), to the Co-PET, or to the mixture of polymers. Useful additives can include, for example, delusterants, nucleating agents, heat stabilizers, viscosity boosters, optical brighteners, antioxidants, antimicrobials, plasticizers, anti-static agents, lubricants, processing aids, flame retardants, dyes, TiO₂, or pigments.

The combined first and second polymers (i.e., a PTT and PET mixture, a PTT and Co-PET mixture, a PBT and PET mixture, or a PBT and Co-PET mixture) are extruded through a spinneret at a temperature of about 250° C. to about 275° C., for example at least about 255° C. and up to about 270° C. The spun filaments are extruded in bundles comprising at least about 34 filaments per threadline, for example from about 175 filaments to about 6800 filaments, or even 6900 filaments or higher. The undrawn filaments typically have a denier per filament in the range of about 3 to about 8, or more. Spinneret orifices are typically round for round fiber cross-sections, but variously shaped orifices can be used as needed, for example for trilobal or delta cross-sections. The spun filaments have a denier in the range of from about 3 to about 8 dpf and are collected as bundles (tow). Typically, the tow has a dry heat shrinkage of less than 6% as determined by the Dry Heat Shrinkage Method disclosed herein in the Examples.

In the second stage of the process to prepare staple fiber, tow is fed from a set of cans or a creel containing undrawn melt spun yarns. Finish may be applied to facilitate processing downstream. Tow is then then drawn while immersed in a heated dilute finish water bath. In general feed roll is kept at room temperature while the draw roll may be heated. Drawn tow is stabilized by passing it through a saturated steam chamber and can be optionally further drawn and annealed over a number of heated draw roll modules before passing it over a room temperature roll module. Various simplifications of the draw zone are possible with less or more heater or room temperature draw module to optimally draw and stabilize yarn in preparation for crimping. Crimping module typically uses a steam box that reduces yarn modulus in preparation for crimping, Typically, the crimper is a mechanical stuffer box type crimper with a flapper gate, acted upon by pneumatic pressure. Yarn tow is pulled into the crimper box by a set of driven rolls; yarn buckles and forms crimp as the flow out of the box is controlled by back pressure on the flapper. Crimped tow passes through an annealer section prior to being cut into staple.

The final denier per filament of the melt spun staple fiber may range from 1-2 for cotton system processing and from 2-3 for wool system processing.

The melt spun staple fibers disclosed herein offer processing advantages. For example, the staple fiber can be processed with good productivity through opening, carding, and drawing steps in making spun yarns. The melt spun staple fibers disclosed herein may be run on a staple spinning process using conditions typical for PET staple spinning.

The drawn fiber can be cut into staple of any desired length. If the staple fiber is too short, it can be difficult to card. If it is too long, it can be difficult to spin on cotton or woolen system equipment. For use in the cotton system, the staple fiber typically has a length in the range of from about 32 mm to about 51 mm, for example in the range of from about 38 to 40 mm. For use in the worsted system, the staple fiber typically has multiple cut lengths with an average cut length in the range of from about 70 mm to about 100 mm, for example in the range of from about 80 mm to about 90 mm. The staple fiber can be crimped to have full sinus arc from about 10 to about 18, for example about 11 to about 15, crimps per inch. For cotton system, the melt spun staple fiber typically has 1-2 denier per filament, a tenacity greater than 4 g/denier, and a break elongation of 20-60%, as determined using methods disclosed in the Examples herein below. For worsted system, melt spun staple fiber typically has 2-4 denier per filament, a tenacity greater than 4 g/denier, and a break elongation of 30-90%.

The melt spun staple fiber disclosed herein can be used to make spun yarn. In one embodiment, the spun yarn consists essentially of the melt spun staple fiber, and does not contain any other type of staple fiber. In another embodiment, the spun yarn comprises the melt spun staple fiber disclosed herein. In a further embodiment, the spun yarn further comprises a second staple fiber in an amount from about 5 weight percent to about 95 weight percent, based on the total weight of the spun yarn. In one embodiment, the second staple fiber can comprise at least one natural fiber. In a further embodiment, the second staple fiber comprises at least one natural fiber selected from cotton, linen, wool, angora, mohair, alpaca, or cashmere. In another embodiment, the second staple can comprise at least one synthetic fiber. In a further embodiment, the second staple fiber comprises polylactic acid, acrylic, nylon, olefin, acetate, rayon, or polyester. In yet another embodiment, the second staple fiber can comprise at least one regenerated cellulose fiber. As used herein, the term “regenerated cellulose fiber” means a textile fiber made from regenerated cellulose, also referred to as rayon, and includes lyocell, viscose, Modal®, and Tencel® fibers. As used herein, “lyocell” means a form of rayon which consists of cellulose fiber made from dissolving bleached wood pulp using dry jet-wet spinning. As used herein, “viscose” means a regenerated manufactured fiber made from cellulose and obtained by the viscose process. As used herein, “Modal®” means fiber made from wood pulp from beech trees. As used herein, “Tencel®” means fiber made from eucalyptus trees.

In one embodiment, the spun yarn comprises melt spun staple fiber comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of from about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising cotton. In a further embodiment, the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of from about 90:10 to about 10:90, for example from about 90:10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising cotton. The cotton can be present in the spun yarn in an amount from about 5 wt % to about 95 wt %, and the melt spun staple fiber can be present in the spun yarn in an amount from about 95 wt % to about 5 wt %, based on the total weight of the spun yarn. For example, the spun yarn can contain about 5 wt % cotton and about 95 wt % melt spun staple fiber, or about 10 wt % cotton and about 90 wt % melt spun staple fiber, or about 15 wt % cotton and about 85 wt % melt spun staple fiber, or about 20 wt % cotton and about 80 wt % melt spun staple fiber, or about 25 wt % cotton and about 75 wt % melt spun staple fiber, or about 30 wt % cotton and about 70 wt % melt spun staple fiber, or about 35 wt % cotton and about 65 wt % melt spun staple fiber, or about 40 wt % cotton and about 60 wt % melt spun staple fiber, or about 45 wt % cotton and about 55 wt % melt spun staple fiber, or about 50 wt % cotton and about 50 wt % melt spun staple fiber, or about 55 wt % cotton and about 45 wt % melt spun staple fiber, or about 60 wt % cotton and about 40 wt % melt spun staple fiber, or about 65 wt % cotton and about 35 wt % melt spun staple fiber, or about 70 wt % cotton and about 30 wt % melt spun staple fiber, or about 75 wt % cotton and about 25 wt % melt spun staple fiber, or about 80 wt % cotton and about 20 wt % melt spun staple fiber, based on the total weight of the spun yarn. In another embodiment, the spun yarn can comprise the melt spun staple fiber at greater than 95 wt % and the second staple fiber comprising cotton at less than 5 wt %. The relative amounts of cotton and melt spun staple fiber are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn. The spun yarn can have a cotton count (Ne) of about 4 to about 70, for example from about 4 to about 60, or from about 4 to about 50, or from about 10 to about 60, or from about 20 to about 60. The spun yarn comprising cotton can have a tenacity at break of at least 10 cN/tex. In some embodiments the spun yarn comprising cotton can have a tenacity at break of at least 10 cN/tex. The spun yarn comprising cotton can have an elongation at break of at least 4%. Methods to determine tenacity and elongation at break are provided in the Examples herein below.

In another embodiment, the spun yarn comprises melt spun staple fiber comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of from about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising wool. In a further embodiment, the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of from about 90:10 to about 10:90, for example from about 90:10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising wool. The term “wool” refers to the fiber from fleece of sheep or lamb. The wool can be present in an amount from about 5 wt % to about 95 wt %, and the melt spun staple fiber can be present in an amount from about 95 wt % to about 5 wt %, based on the total weight of the spun yarn. For example, the spun yarn can contain about 5 wt % wool and about 95 wt % melt spun staple fiber, or about 10 wt % wool and about 90 wt % melt spun staple fiber, or about 15 wt % wool and about 85 wt % melt spun staple fiber, or about 20 wt % wool and about 80 wt % melt spun staple fiber, or about 25 wt % wool and about 75 wt % melt spun staple fiber, or about 30 wt % wool and about 70 wt % melt spun staple fiber, or about 35 wt % wool and about 65 wt % melt spun staple fiber, or about 40 wt % wool and about 60 wt % melt spun staple fiber, or about 45 wt % wool and about 55 wt % melt spun staple fiber, or about 50 wt % wool and about 50 wt % melt spun staple fiber, or about 55 wt % wool and about 45 wt % melt spun staple fiber, or about 60 wt % wool and about 40 wt % melt spun staple fiber, or about 65 wt % wool and about 35 wt % melt spun staple fiber, or about 70 wt % wool and about 30 wt % melt spun staple fiber, or about 75 wt % wool and about 25 wt % melt spun staple fiber, or about 80 wt % wool and about 20 wt % melt spun staple fiber, or about 85 wt % wool and about 15 wt % melt spun staple fiber, or about 90 wt % wool and about 10 wt % melt staple fiber, or about 95 wt % wool and about 5 wt % melt spun staple fiber, based on the total weight of the spun yarn. The relative amounts of wool and melt spun staple fiber are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn. The spun yarn can have a worsted count (Nm) of about 7 to about 120, for example from about 7 to about 110, or from about 7 to about 100, or from about 10 to about 120, or from about 10 to about 100, or from about 10 to about 75.

In another embodiment, the spun yarn comprises melt spun staple fiber comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of from about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising rayon. In a further embodiment, the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of from about 90:10 to about 10:90, for example from about 90:10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising rayon. As used herein, “rayon” means textile fiber made from regenerated cellulose and includes lyocell, viscose, Modal®, and Tencel® fibers. In the spun yarn, the rayon can be present in an amount from about 5 wt % to about 95 wt %, and the melt spun staple fiber can be present in an amount from about 95 wt % to about 5 wt %, based on the total weight of the spun yarn. For example, the spun yarn can contain about 5 wt % rayon and about 95 wt % melt spun staple fiber, or about 10 wt % rayon and about 90 wt % melt spun staple fiber, or about 15 wt % rayon and about 85 wt % melt spun staple fiber, or about 20 wt % rayon and about 80 wt % melt spun staple fiber, or about 25 wt % rayon and about 75 wt % melt spun staple fiber, or about 30 wt % rayon and about 70 wt % melt spun staple fiber, or about 35 wt % rayon and about 65 wt % melt spun staple fiber, or about 40 wt % rayon and about 60 wt % melt spun staple fiber, or about 45 wt % rayon and about 55 wt % melt spun staple fiber, or about 50 wt % rayon and about 50 wt % melt spun staple fiber, or about 55 wt % rayon and about 45 wt % melt spun staple fiber, or about 60 wt % rayon and about 40 wt % melt spun staple fiber, or about 65 wt % rayon and about 35 wt % melt spun staple fiber, or about 70 wt % rayon and about 30 wt % melt spun staple fiber, or about 75 wt % rayon and about 25 wt % melt spun staple fiber, or about 80 wt % rayon and about 20 wt % melt spun staple fiber, or about 85 wt % rayon and about 15 wt % melt spun staple fiber, or about 90 wt % rayon and about 10 wt % melt staple fiber, or about 95 wt % rayon and about 5 wt % melt spun staple fiber, based on the total weight of the spun yarn. The relative amounts of rayon and melt spun staple fiber are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn. The spun yarn can have a cotton count (Ne) of about 4 to about 80,for example from about 10 to about 60, or from about 12 to about 40.

In another embodiment, the spun yarn comprises melt spun staple fiber comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of from about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising acrylic. In a further embodiment, the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of from about 90:10 to about 10:90, for example from about 90:10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising acrylic. As used herein, “acrylic fiber” means synthetic fibers made from a polyacrylonitrile having an average molecular weight of −100,000, about 1900 monomer units. The acrylic fiber can be present in an amount from about 5 wt % to about 95 wt %, and the melt spun staple fiber can be present in an amount from about 95 wt % to about 5 wt %, based on the total weight of the spun yarn. For example, the spun yarn can contain about 5 wt % acrylic fiber and about 95 wt % melt spun staple fiber, or about 10 wt % acrylic fiber and about 90 wt % melt spun staple fiber, or about 15 wt % acrylic fiber and about 85 wt % melt spun staple fiber, or about 20 wt % acrylic fiber and about 80 wt % melt spun staple fiber, or about 25 wt % acrylic fiber and about 75 wt % melt spun staple fiber, or about 30 wt % acrylic fiber and about 70 wt % melt spun staple fiber, or about 35 wt % acrylic fiber and about 65 wt % melt spun staple fiber, or about 40 wt % acrylic fiber and about 60 wt % melt spun staple fiber, or about 45 wt % acrylic fiber and about 55 wt % melt spun staple fiber, or about 50 wt % acrylic fiber and about 50 wt % melt spun staple fiber, or about 55 wt % acrylic fiber and about 45 wt % melt spun staple fiber, or about 60 wt % acrylic fiber and about 40 wt % melt spun staple fiber, or about 65 wt % acrylic fiber and about 35 wt % melt spun staple fiber, or about 70 wt % acrylic fiber and about 30 wt % melt spun staple fiber, or about 75 wt % acrylic fiber and about 25 wt % melt spun staple fiber, or about 80 wt % acrylic fiber and about 20 wt % melt spun staple fiber, or about 85 wt % acrylic fiber and about 15 wt % melt spun staple fiber, or about 90 wt % acrylic fiber and about 10 wt % melt staple fiber, or about 95 wt % acrylic fiber and about 5 wt % melt spun staple fiber, based on the total weight of the spun yarn. The relative amounts of acrylic fiber and melt spun staple fiber are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn. The spun yarn can have a cotton count (Ne) of about 4 to about 80, for example from about 10 to about 60, or from about 12 to about 40.

In another embodiment, the spun yarn comprises melt spun staple fiber comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of from about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising polylactic acid (PLA). In a further embodiment, the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of from about 90:10 to about 10:90, for example from about 90:10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising PLA. As used herein, “polylactic fiber” means a manufactured fiber in which the fiber-forming substance is composed of at least 85% by weight of lactic acid ester units derived from naturally occurring sugars. The PLA can be present in an amount from about 5 wt % to about 95 wt %, and the melt spun staple fiber can be present in an amount from about 95 wt % to about 5 wt %, based on the total weight of the spun yarn. For example, the spun yarn can contain about 5 wt % PLA and about 95 wt % melt spun staple fiber, or about 10 wt % PLA and about 90 wt % melt spun staple fiber, or about 15 wt % PLA and about 85 wt % melt spun staple fiber, or about 20 wt % PLA and about 80 wt % melt spun staple fiber, or about 25 wt % PLA and about 75 wt % melt spun staple fiber, or about 30 wt % PLA and about 70 wt % melt spun staple fiber, or about 35 wt % PLA and about 65 wt % melt spun staple fiber, or about 40 wt % PLA and about 60 wt % melt spun staple fiber, or about 45 wt % PLA and about 55 wt % melt spun staple fiber, or about 50 wt % PLA and about 50 wt % melt spun staple fiber, or about 55 wt % PLA and about 45 wt % melt spun staple fiber, or about 60 wt % PLA and about 40 wt % melt spun staple fiber, or about 65 wt % PLA and about 35 wt % melt spun staple fiber, or about 70 wt % PLA and about 30 wt % melt spun staple fiber, or about 75 wt % PLA and about 25 wt % melt spun staple fiber, or about 80 wt % PLA and about 20 wt % melt spun staple fiber, or about 85 wt % PLA and about 15 wt % melt spun staple fiber, or about 90 wt % PLA and about 10 wt % melt staple fiber, or about 95 wt % PLA and about 5 wt % melt spun staple fiber, based on the total weight of the spun yarn. The relative amounts of PLA and melt spun staple fiber are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn.

In another embodiment, the spun yarn comprises melt spun staple fiber comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of from about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising nylon. In a further embodiment, the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of from about 90:10 to about 10:90, for example from about 90:10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising nylon. As used herein, “nylon fiber” means a manufactured fiber in which the fiber-forming substance is a long chain synthetic polyamide in which less than 85% of the amide linkages are attached directly to two aliphatic groups. The nylon can be present in an amount from about 5 wt % to about 95 wt %, and the melt spun staple fiber can be present in an amount from about 95 wt % to about 5 wt %, based on the total weight of the spun yarn. For example, the spun yarn can contain about 5 wt % nylon and about 95 wt % melt spun staple fiber, or about 10 wt % nylon and about 90 wt % melt spun staple fiber, or about 15 wt % nylon and about 85 wt % melt spun staple fiber, or about 20 wt % nylon and about 80 wt % melt spun staple fiber, or about 25 wt % nylon and about 75 wt % melt spun staple fiber, or about 30 wt % nylon and about 70 wt % melt spun staple fiber, or about 35 wt % nylon and about 65 wt % melt spun staple fiber, or about 40 wt % nylon and about 60 wt % melt spun staple fiber, or about 45 wt % nylon and about 55 wt % melt spun staple fiber, or about 50 wt % nylon and about 50 wt % melt spun staple fiber, or about 55 wt % nylon and about 45 wt % melt spun staple fiber, or about 60 wt % nylon and about 40 wt % melt spun staple fiber, or about 65 wt % nylon and about 35 wt % melt spun staple fiber, or about 70 wt % nylon and about 30 wt % melt spun staple fiber, or about 75 wt % nylon and about 25 wt % melt spun staple fiber, or about 80 wt % nylon and about 20 wt % melt spun staple fiber, or about 85 wt % nylon and about 15 wt % melt spun staple fiber, or about 90 wt % nylon and about 10 wt % melt staple fiber, or about 95 wt % nylon and about 5 wt % melt spun staple fiber, based on the total weight of the spun yarn. The relative amounts of nylon and melt spun staple fiber are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn.

In another embodiment, the spun yarn comprises melt spun staple fiber comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of from about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising olefin. In a further embodiment, the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of from about 90:10 to about 10:90, for example from about 90:10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising olefin. As used herein, “olefin fiber” means a manufactured fiber in which the fiber-forming substance is any long chain synthetic polymer composed of at least 85% by weight of ethylene, propylene, or other olefin units, except amorphous (noncrystalline) polyolefins qualifying as a rubber fiber. The olefin fiber can be present in an amount from about 5 wt % to about 95 wt %, and the melt spun staple fiber can be present in an amount from about 95 wt % to about 5 wt %, based on the total weight of the spun yarn. For example, the spun yarn can contain about 5 wt % olefin fiber and about 95 wt % melt spun staple fiber, or about 10 wt % olefin fiber and about 90 wt % melt spun staple fiber, or about 15 wt % olefin fiber and about 85 wt % melt spun staple fiber, or about 20 wt % olefin fiber and about 80 wt % melt spun staple fiber, or about 25 wt % olefin fiber and about 75 wt % melt spun staple fiber, or about 30 wt % olefin fiber and about 70 wt % melt spun staple fiber, or about 35 wt % olefin fiber and about 65 wt % melt spun staple fiber, or about 40 wt % olefin fiber and about 60 wt % melt spun staple fiber, or about 45 wt % olefin fiber and about 55 wt % melt spun staple fiber, or about 50 wt % olefin fiber and about 50 wt % melt spun staple fiber, or about 55 wt % olefin fiber and about 45 wt % melt spun staple fiber, or about 60 wt % olefin fiber and about 40 wt % melt spun staple fiber, or about 65 wt % olefin fiber and about 35 wt % melt spun staple fiber, or about 70 wt % olefin fiber and about 30 wt % melt spun staple fiber, or about 75 wt % olefin fiber and about 25 wt % melt spun staple fiber, or about 80 wt % olefin fiber and about 20 wt % melt spun staple fiber, or about 85 wt % olefin fiber and about 15 wt % melt spun staple fiber, or about 90 wt % olefin fiber and about 10 wt % melt staple fiber, or about 95 wt % olefin fiber and about 5 wt % melt spun staple fiber, based on the total weight of the spun yarn. The relative amounts of olefin fiber and melt spun staple fiber are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn.

In another embodiment, the spun yarn comprises melt spun staple fiber comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of from about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising acetate. In a further embodiment, the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of from about 90:10 to about 10:90, for example from about 90:10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising acetate. As used herein, “acetate fiber” means a manufactured fiber in which the fiber-forming substance is cellulose acetate, and includes diacetate and triacetate. Diacetate is defined as cellulose acetate fiber for which more than 74% and less than 92% of the hydroxyl groups has been acetylated (degree of esterification above 2.22 and below 2.76). Triacetate is defined as cellulose acetate fiber for which more than 92% of the hydroxyl groups has been acetylated (degree of esterification above 2.76 and below 3.00). The acetate fiber can be present in an amount from about 5 wt % to about 95 wt %, and the melt spun staple fiber can be present in an amount from about 95 wt % to about 5 wt %, based on the total weight of the spun yarn. For example, the spun yarn can contain about 5 wt % acetate fiber and about 95 wt % melt spun staple fiber, or about 10 wt % acetate fiber and about 90 wt % melt spun staple fiber, or about 15 wt % acetate fiber and about 85 wt % melt spun staple fiber, or about 20 wt % acetate fiber and about 80 wt % melt spun staple fiber, or about 25 wt % acetate fiber and about 75 wt % melt spun staple fiber, or about 30 wt % acetate fiber and about 70 wt % melt spun staple fiber, or about 35 wt % acetate fiber and about 65 wt % melt spun staple fiber, or about 40 wt % acetate fiber and about 60 wt % melt spun staple fiber, or about 45 wt % acetate fiber and about 55 wt % melt spun staple fiber, or about 50 wt % acetate fiber and about 50 wt % melt spun staple fiber, or about 55 wt % acetate fiber and about 45 wt % melt spun staple fiber, or about 60 wt % acetate fiber and about 40 wt % melt spun staple fiber, or about 65 wt % acetate fiber and about 35 wt % melt spun staple fiber, or about 70 wt % acetate fiber and about 30 wt % melt spun staple fiber, or about 75 wt % acetate fiber and about 25 wt % melt spun staple fiber, or about 80 wt % acetate fiber and about 20 wt % melt spun staple fiber, or about 85 wt % acetate fiber and about 15 wt % melt spun staple fiber, or about 90 wt % acetate fiber and about 10 wt % melt staple fiber, or about 95 wt % acetate fiber and about 5 wt % melt spun staple fiber, based on the total weight of the spun yarn. The relative amounts of acetate fiber and melt spun staple fiber are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn.

In another embodiment, the spun yarn comprises melt spun staple fiber comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of from about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising a polyester, for example poly(ethylene terephthalate), poly(trimethylene terephthalate), or poly (butylene terephthalate). In a further embodiment, the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of from about 90:10 to about 10:90, for example from about 90:10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising a polyester. The polyester can be present in an amount from about 5 wt % to about 95 wt %, and the melt spun staple fiber can be present in an amount from about 95 wt % to about 5 wt %, based on the total weight of the spun yarn. For example, the spun yarn can contain about 5 wt % polyester fiber and about 95 wt % melt spun staple fiber, or about 10 wt % polyester fiber and about 90 wt % melt spun staple fiber, or about 15 wt % polyester fiber and about 85 wt % melt spun staple fiber, or about 20 wt % polyester fiber and about 80 wt % melt spun staple fiber, or about 25 wt % polyester fiber and about 75 wt % melt spun staple fiber, or about 30 wt % polyester fiber and about 70 wt % melt spun staple fiber, or about 35 wt % polyester fiber and about 65 wt % melt spun staple fiber, or about 40 wt % polyester fiber and about 60 wt % melt spun staple fiber, or about 45 wt % polyester fiber and about 55 wt % melt spun staple fiber, or about 50 wt % polyester fiber and about 50 wt % melt spun staple fiber, or about 55 wt % polyester fiber and about 45 wt % melt spun staple fiber, or about 60 wt % polyester fiber and about 40 wt % melt spun staple fiber, or about 65 wt % polyester fiber and about 35 wt % melt spun staple fiber, or about 70 wt % polyester fiber and about 30 wt % melt spun staple fiber, or about 75 wt % polyester fiber and about 25 wt % melt spun staple fiber, or about 80 wt % polyester fiber and about 20 wt % melt spun staple fiber, or about 85 wt % polyester fiber and about 15 wt % melt spun staple fiber, or about 90 wt % polyester fiber and about 10 wt % melt staple fiber, or about 95 wt % polyester fiber and about 5 wt % melt spun staple fiber, based on the total weight of the spun yarn. The relative amounts of polyester fiber and melt spun staple fiber are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn. The spun yarn can have a cotton count (Ne) of about 4 to about 80, for example from about 10 to about 60, or from about 12 to about 40.

The melt spun staple fibers are cut to lengths as desired for blending with a second fiber and subsequent processing on the cotton or woolen system. For example, spun yarns comprising the melt spun staple fiber and cotton, linen, polylactic acid, acrylic, nylon, olefin, acetate, polyester, or rayon fiber typically can be processed on the cotton system. Spun yarns comprising the melt spun staple fiber and wool, angora, mohair, or cashmere fiber typically can be processed on the woolen system.

To form the spun yarns, the melt spun staple fibers, and optionally at least one second staple fiber, are first blended, for example by stack mixing, a process in which fiber bales are opened, mixed, and laid in layers. Fiber bundles can be opened to smaller sized fiber tufts, for example in a blow room using a sequence of coarse opening machines followed by fine opening machines. The smaller fiber bundles are then carded to form a continuous fiber strand, referred to as sliver, where almost all the fibers are oriented along the sliver axis. Sliver from a carding machine can have very high mass/length variation, so typically a number of carding slivers (i.e. 6) are combined and simultaneously drafted by the same amount (i.e., 6X) to further orient the fibers in the resultant sliver, for example with a draw frame machine or other methods known in the art. The sliver delivered from the final draw frame has minimal mass/length variation but high linear density compared to the linear density desired in the final spun yarn, so the linear density of the sliver is reduced in a drawing process. Typically the drawing process is operated in two steps, in which partial drafting and twisting are performed to prepare the roving. The roving is converted to spun yarn by drafting it further on a final spinning machine using known processes such as ring, open end, air jet, and vortex spinning. The spun yarn can be wound onto a small package referred to as a cop in ring spinning; several cops can be joined and wound onto a larger final package referred to as a cone.

Woven and knitted fabrics can be made from the spun yarns disclosed herein. Stretch fabric examples include circular, flat, and warp knits, and plain, twill, and satin wovens. Articles such as garments can be made from fabrics comprising the spun yarns disclosed herein. Nonwoven fabrics can be made from the staple fibers disclosed herein, and can be useful in articles such as wipes, diapers, napkins, and personal care items. Nonwoven fabrics can also be used as the base material for coated fabrics and in a variety of other applications, such as apparel and home furnishings.

The spun yarns disclosed herein are useful in making fabrics, such as woven or knit fabrics. In one embodiment, a fabric comprising a spun yarn as disclosed herein is a woven fabric having a warp and a weft. In one embodiment, the warp comprises a spun yarn as disclosed herein. In another embodiment, the weft comprises a spun yarn as disclosed herein. In an additional embodiment, the warp and the weft each comprise a spun yarn as disclosed herein. The woven fabric can further comprise additional yarns or continuous filament, for example in the warp, in the weft, or in both the warp and the weft. In another embodiment, spun yarn as disclosed herein is used in the warp, and a spun yarn comprising a natural fiber is used in the weft. In another embodiment, spun yarn as disclosed herein is used in the warp, and a spun yarn comprising a synthetic fiber is used in the weft. In yet another embodiment, a spun yarn comprising a natural fiber is used in the warp and a spun yarn as disclosed herein is used in the weft. In a further embodiment, a spun yarn comprising a synthetic fiber is used in the warp and a spun yarn as disclosed herein is used in the weft. In still another embodiment, spun yarn as disclosed herein is used in the warp and also in the weft. Knit fabrics can be made using only the spun yarns disclosed herein, or in conjunction with a spun yarn comprising a natural or a synthetic fiber. Woven fabrics comprising spun yarns as disclosed herein can have a fabric weight in the range of about 80 g/m² to about 600 g/m², for example.

Fabrics comprising spun yarns as disclosed herein can offer advantages over fabrics of the same construction consisting of spun yarns of PET, cotton, rayon, PTT, or a combination thereof, and lacking the melt spun staple fibers disclosed herein. For example, fabrics comprising spun yarns comprising melt spun staple fibers as disclosed herein can have softer hand (i.e. feel softer) than fabrics of PET, cotton, rayon, or a combination thereof, as well as greater bulk, as indicated by greater fabric thickness. Fabrics comprising the spun yarns disclosed herein can have better dyeability than a fabric of the same construction consisting of PET, cotton, rayon, or a combination thereof. Compared to PET fabrics of similar construction, the fabrics disclosed herein can dye more deeply, darker, and at lower temperatures. The fabrics disclosed herein can have better dye pickup than PET fabrics when dyed at a lower temperature, which offers reduced cost through energy savings. For example, fabrics containing the spun yarns disclosed herein can dye darker (i.e. have lower L* values when measured under a D65 light source) than PET fabrics when dyed simultaneously, and can dye darker than PET fabric even when dyed at 100° C. and with comparison PET fabrics dyed at 130° C. The properties of picking up more dye, picking up dye at lower temperature, and dyeing more deeply can be referred to as “better dyeability” of a fabric. The woven fabrics disclosed herein can also have improved drape, for example as demonstrated by higher area of drape and drape coefficient values, for example as determined by method BS 5058. Especially desirable in a fabric is the combination of softer hand and improved drape. Additionally, the fabrics disclosed herein demonstrated less pilling (higher pill rating values) than fabrics of the same construction consisting of PET, cotton, rayon, or a combination thereof, for example as determined by the ASTM D4970 method, and better abrasion resistance. The fabrics disclosed herein can also have better tear strength in the warp and/or weft direction than fabrics of the same construction consisting of PET, cotton, rayon, or a combination thereof. Knit fabrics comprising spun yarns as disclosed herein can have higher recovery than a knit fabric of the same construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.

Non-limiting examples of the embodiments disclosed herein include:

-   1. A spun yarn comprising: melt spun staple fiber comprising a first     polymer comprising poly(trimethylene terephthalate) (PTT) or     poly(butylene terephthalate) (PBT) and a second polymer comprising     poly(ethylene terephthalate) (PET) or Co-PET, wherein Co-PET is a     poly(ethylene terephthalate) copolymer comprising isophthalic acid     monomer; and wherein the first polymer comprises poly(trimethylene     terephthalate) and the weight ratio of the poly(trimethylene     terephthalate) to the second polymer is in the range of from about     80:20 to about 10:90; or the first polymer comprises poly(butylene     terephthalate) and the weight ratio of the poly(butylene     terephthalate) to the second polymer is in the range of from about     90:10 to about 10:90. -   2. The spun yarn of embodiment 1, wherein the first polymer     comprises poly(trimethylene terephthalate) and the second polymer     comprises poly(ethylene terephthalate). -   3. The spun yarn of embodiment 1 or 2, wherein the first polymer     comprises poly(trimethylene terephthalate) and the second polymer     comprises Co-PET. -   4. The spun yarn of embodiment 1, wherein the first polymer     comprises poly(butylene terephthalate) and the second polymer     comprises poly(ethylene terephthalate). -   5. The spun yarn of embodiment 1 or 4, wherein the first polymer     comprises poly(butylene terephthalate) and the second polymer     comprises Co-PET. -   6. The spun yarn of embodiment 1, 3, or 5, wherein the second     polymer comprises Co-PET, and the Co-PET contains from about 0.5     mole percent to about 10 mole percent isophthalic acid monomer,     based on the total copolymer composition. -   7. The spun yarn of embodiment 1, 2, 3, 4, 5, or 6, wherein the     weight ratio is in the range of about 70:30 to about 30:70. -   8. The spun yarn of embodiment 1, 2, 3, 4, 5, or 6, wherein the     weight ratio is in the range of about 60:40 to about 40:60. -   9. The spun yarn of embodiment 1, 2, 3, 4, 5, or 6, wherein the     weight ratio is in the range of about 70:30 to about 50:50. -   10. The spun yarn of spun yarn of embodiment 1, 2, 3, 4, 5, 6, or 7,     wherein the weight ratio of the poly(trimethylene terephthalate) or     the poly(butylene terephthalate) to the second polymer is in the     range of about 70:30 to about 30:70. -   11. The spun yarn of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10,     wherein the spun yarn has a boil off shrinkage of at least about 6%     as determined according to ASTM D2259. -   12. The spun yarn of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or 11     further comprising a second staple fiber in an amount from about 5     wt % to about 95 wt %, based on the total weight of the spun yarn. -   13. The spun yarn of embodiment 12, wherein the second staple fiber     comprises polylactic acid, acrylic, nylon, olefin, acetate, rayon,     polyester, cotton, linen, wool, angora, mohair, alpaca, cashmere, or     a mixture thereof. -   14. The spun yarn of embodiment 12, wherein the second staple fiber     comprises cotton or wool. -   15. The spun yarn of embodiment 12, 13, or 14, wherein the second     staple fiber comprises cotton. -   16. The spun yarn of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,     12, 13, 14, or 15, wherein the spun yarn has a cotton count of about     4 Ne to about 80 Ne. -   17. The spun yarn of embodiment 12, 13, or 14, wherein the second     staple fiber comprises wool. -   18. The spun yarn of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,     12, 13, 14, or 17, wherein the spun yarn has a worsted count in the     range of from 7 Nm to 120 Nm. -   19. A fabric comprising a spun yarn of embodiment 1, 2, 3, 4, 5, 6,     7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18. -   20. A fabric of embodiment 19, wherein the fabric has a softer hand     and better drape than a fabric of the same fabric construction     consisting of rayon, polyethylene terephthalate, cotton, or a     combination thereof. -   21. A fabric of embodiment 19 or 20, wherein the fabric has better     dyeability than a fabric of the same fabric construction consisting     of polyethylene terephthalate, cotton, rayon, or a combination     thereof. -   22. A fabric of embodiment 19, 20, or 21, wherein the fabric has     better abrasion resistance as determined according to ASTM D4966     Standard Test Method than a fabric of the same fabric construction     consisting of polyethylene terephthalate, cotton, rayon, or a     combination thereof. -   23. A fabric of embodiment 19, 20, 21, or 22, wherein the fabric has     less pilling (higher pill rating values) as determined according to     ASTM D4970 Standard Test Method than a fabric of the same fabric     construction consisting of polyethylene terephthalate, cotton,     rayon, or a combination thereof. -   24. A fabric of embodiment 19, 20, 21, 22, or 23, wherein the fabric     has greater bulk as determined according to ASTM D1777 Standard Test     Method than a fabric of the same fabric construction consisting of     polyethylene terephthalate, cotton, rayon, or a combination thereof. -   25. A fabric of embodiment 19, 20, or 21, wherein the fabric has at     least one of:     -   i) better abrasion resistance as determined according to ASTM         D4966 Standard Test Method;     -   ii) higher pill rating values as determined according to ASTM         D4970 Standard Test Method; or     -   iii) greater bulk as determined according to ASTM D1777 Standard         Test Method; than a fabric of the same fabric construction         consisting of polyethylene terephthalate, cotton, rayon, or a         combination thereof. -   26. A fabric of embodiment 19, 20, 21, 22, 23, 24, or 25, wherein     the fabric is a woven fabric having a warp and a weft. -   27. A fabric of embodiment 26, wherein the warp comprises a spun     yarn of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14,     15, 16, 17, or 18. -   28. A fabric of embodiment 26 or 27, wherein the weft comprises a     spun yarn of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13,     14, 15, 16, 17, or 18. -   29. A fabric of embodiment 26, 27, or 28, wherein both the warp and     the weft each comprise a spun yarn of embodiment 1, 2, 3, 4, 5, 6,     7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18. -   30. A fabric of embodiment 19, 20, 21, 22, 23, 24, or 25, wherein     the fabric is a knit fabric. -   31. A fabric of embodiment 30, wherein the knit fabric has higher     recovery as determined according to Method BS 4294 than a knit     fabric of the same fabric construction consisting of polyethylene     terephthalate, cotton, rayon, or a combination thereof. -   32. An article comprising a fabric of embodiment 19, 20, 21, 22, 23,     24, 25, 26, 27, 28, 29, 30, or 31. -   33. An article of embodiment 32, wherein the article is a garment. -   34. Melt spun staple fiber comprising a first polymer comprising     poly(trimethylene terephthalate) or poly(butylene terephthalate) and     a second polymer comprising poly(ethylene terephthalate) or Co-PET,     wherein Co-PET is a poly(ethylene terephthalate) copolymer     comprising isophthalic acid monomer, the staple fiber having:     -   a) a weight ratio of poly(trimethylene terephthalate) to the         second polymer in the range of from about 80:20 to about 10:90;         or         -   a weight ratio of poly(butylene terephthalate) to the second             polymer in the range of from about 90:10 to about 10:90; and     -   b) a dry heat shrinkage of less than 6% as determined by the Dry         Heat Shrinkage Method. -   35. Melt spun staple fiber of embodiment 34, wherein the weight     ratio of the poly(trimethylene terephthalate) or the poly(butylene     terephthalate) to the second polymer is in the range of about 70:30     to about 30:70. -   36. Melt spun staple fiber of embodiment 34, wherein the weight     ratio of the poly(trimethylene terephthalate) or the poly(butylene     terephthalate) to the second polymer is in the range of about 70:30     to about 50:50. -   37. Melt spun staple fiber of embodiment 34, 35, or 36, wherein the     first polymer comprises poly(trimethylene terephthalate) and the     second polymer comprises poly(ethylene terephthalate). -   38. Melt spun staple fiber of embodiment 34, 35, or 36, wherein the     first polymer comprises poly(trimethylene terephthalate) and the     second polymer comprises Co-PET. -   39. Melt spun staple fiber of embodiment 34, 35, or 36, wherein the     first polymer comprises poly(butylene terephthalate) and the second     polymer comprises poly(ethylene terephthalate). -   40. Melt spun staple fiber of embodiment 34, 35, or 36, wherein the     first polymer comprises poly(butylene terephthalate) and the second     polymer comprises Co-PET. -   41. Melt spun staple fiber of embodiment 34, 35, 36, 38, or 40,     wherein the second polymer comprises Co-PET, and the Co-PET contains     from about 0.5 mole percent to about 10 mole percent isophthalic     acid monomer, based on the total copolymer composition.

EXAMPLES

As used herein, “Comp. Ex.” Means Comparative Example; “Ex.” means Example; “rpm” means revolutions per minute; “wt %” means weight percent; “dL/g” is deciliters per gram; “g” is gram(s); “mg” is millligram(s); “° C.” means degrees Celsius; “min” is minute(s); “h” is hour(s); “s” is second(s); “lb” is pound(s); “kg” is kilogram(s); “mm” is millimeter(s); “m” is meter(s); “gpl” is grams per liter; “m/min” is meters per minute; “mol” is mole; “kg” is kilogram(s); “ppm” is parts per million; “Hz” is hertz; “cN” is centiNewton(s); “rpm” is revolutions per minute; “wt” is weight; “dpf” is denier per filament; “g/d” is grams per denier; “Ne” means cotton count (English) and is a measure of linear density defined as the number hanks (850 yards or 770 meters) of skein material that weight 1 pound (0.45 kg); “Nm” means metric count and refers to the number of 1000 meter units in a kilogram of yarn; “dtex” means decitex; “AATCC” means American Association of Textile Chemists and Colorists; “ASTM” means American Society for Testing and Materials; and “BS” means British Standards Institution.

Materials

Unless otherwise noted, all materials were used as received.

Polytrimethylene terephthalate (PTT) containing 0.3% TiO₂ and having an intrinsic viscosity of 0.96 dL/g was obtained from E.I. du Pont de Nemours and Company (Wilmington, Del.) as merge K2266.

Co-PET containing 1.7 mol % of isophthalic acid (IPA) monomer, 48.4 mol % of terephthalic acid (TPA) monomer, and 49.9 mol % of ethylene glycol (EG) monomer was obtained from Nan Ya Plastics Corporation, America, P.O. Box 939, Lake City, S.C 29560, USA. The Co-PET composition was determined by NMR analysis and is given based on the total copolymer composition. The Co-PET had an intrinsic viscosity of 0.80 dL/g.

Fiber-grade post-consumer recycled Co-PET, containing 1.1 mol % IPA monomer, 49.1 mol % TPA monomer, and 49.9 mol % of EG monomer was obtained from William Barnet & Son, LLC, P.O. Box 171898, Spartanburg, S.C. 29301, USA. The Co-PET composition was determined by NMR analysis and is given based on the total copolymer composition. The Co-PET had an intrinsic viscosity of 0.76 dL/g.

Methods

“Co-PET” composition was determined by NMR analysis using the following procedure. The Co-PET pellets were cryoground into a powder-like form, then ˜18 mg were weighed into an NMR tube and a solution of 5:1 CDCI3:TFA-D (5:1 deuterated chloroform/deuterated trifluoroacetic acid) added to 0.6 mL total volume. The sample was vortexed to dissolve the Co-PET. A proton NMR spectrum was obtained within 30 minutes of dissolution.

Proton NMR spectra were acquired on a 500 MHz Bruker Avance III HD NMR equipped with 5 mm CPQCI (indirect) cryoprobe at 30° C. The following parameters were used for acquisition: recycle delay of 30 seconds, acquisition time of 4 sec, 90 degree pulse of 8.0 seconds, spectral window of 10000 Hz, 79998 points, a total of 64 scans/transients collected and averaged. The spectrum is referenced to chloroform-d residual proton signal at 7.24 ppm, and processed with lb of 0.10 Hz and zero-filled out to 512 k.

Co-PET composition was calculated from integrals for the signals at approximately 8.7 ppm, 8.1 ppm, and 4.8 ppm corresponding to isophthalic acid, terephthalic acid, and ethylene glycol between terephthalic acid groups, respectively. The isophthalic acid signal used represents 1 mole of protons, so its integral was already relative. The terephthalic acid integral represents 4 moles of terephthalic acid protons and includes 2 moles of isophthalic acid protons; the terephthalic acid relative integral was determined by subtracting 2× the isophthalic acid relative integral, then dividing the remainder by 4. The ethylene glycol-related integral corresponds to 4 moles of ethylene glycol protons, and the relative integral was determined by dividing the measured integral by 4. The three relative integrals were totaled, and the relative mol % values were calculated as each corresponding relative integral divided by the total, then multiplied by 100%.

Dry Heat Shrinkage of undrawn melt spun fiber was determined using the following procedure, which is referred to herein as Dry Heat Shrinkage Method. A 50-cm diameter, 10-loop skein was prepared and its length was measured under a 20 g weight. Two such loops were allowed to shrink by exposure to 40° C. for 20 hours under zero imposed tension. Loops were cooled to 21° C. at 65% relative humidity prior to remeasuring the length under 20 g weight. Dry Heat Shrinkage, as a percentage, was calculated as follows:

% Dry heat shrinkage=(Initial length−length after heating)*100/Initial length

For melt spun staple fiber, an Automatic Single-Fiber Test System FAVIMAT+ was used to determine fiber properties, using the following methods. Denier was determined according to ASTM D1577 Standard Test Methods for Linear Density of Textile Fibers. Tenacity and elongation at break were determined according to ASTM D3822 Tensile Properties of Single Textile Fibers.

Crimp properties of staple fibers are characterized by crimp contraction, crimp stability, and crimp recovery. Crimp contraction is the difference in length of a crimped versus de-crimped fiber. Measuring crimped length, L0, under a low load of 0.001 cN/dtex and de-crimped length, L1, under a heavy load of 0.1 cN/dtex allows one to calculate crimp contraction as [(L1-L0)/L1]*100.

Crimp stability is a measure of stability of crimp under a specified load. It can be measured by determining recovery in staple length when a load is removed. With L2 as the length of staple fiber (measured under 0.001 cN/dtex) 60 sec after a heavier load of 0.1 cN/dtex is applied for 10 sec (to determine L1), crimp stability can be calculated as [(L1-L241-L0)]*100.

Crimp recovery is the difference in length of a de-crimped fiber, L1, and the fiber length after releasing the crimp removal force, L2, expressed as a percentage of de-crimped fiber: [(L1-L2)/L1]*100.

Melt Spun Fiber Examples Comparative Example A Melt Spun PTT Fiber

Polytrimethylene terephthalate (PTT) containing 0.3% TiO₂ and having an intrinsic viscosity of 0.96 dL/g was dried at 120° C. under nitrogen blanket in a vacuum oven for 16 hours and melt-extruded into round cross-section, 34-filament yarn bundle using a twin-screw extruder spinning machine. Extruder melt zone temperatures were maintained from 180-255° C. Polymer throughput was 14.06 g/min with a winder speed of 1250 m/m giving a spun denier per filament of 2.9.

Dry heat shrinkage of yarn bundle was determined to be 47%.

Example 1 Undrawn Melt Spun Fiber Containing PTT and Co-PET

Polytrimethylene terephthalate containing 0.3% TiO₂ and having an intrinsic viscosity of 0.96 dL/g was melt blended with polyethylene terephthalate co-ethylene isophthalate (Co-PET) (from Nan Ya Plastics) having an intrinsic viscosity of 0.80 dL/g in a twin-screw extruder in a 50/50 weight ratio to form compounded pellets. Extruder throughput was 150 lb/h (68.04 kg/h, 0.0189 kg/s) and melt temperature at extruder exit was under 285° C. as measured by a hand-held thermocouple.

PTT:Co-PET compounded pellets were dried at 120° C. under nitrogen blanket in a vacuum oven for 16 hours and melt-extruded into round cross-section, 34-filament yarn bundle using a twin-screw extruder spinning machine.

Extruder melt zone temperatures were maintained from 180-255° C. Polymer throughput was either 14.06 g/min or 21.52 g/min. For each throughput, winder speed was either 750 m/m or 1250 m/m giving a spun denier per filament in the range of from 3.3 to 7.7. Dry heat shrinkage of yarn bundles (tow) was measured to be in the range of 1.2% to 3.1%. This amount of dry heat shrinkage in undrawn fiber is very low and indicates stability of the material during storage. Results are shown in the following Table.

TABLE 1 Example 1 Spinning Conditions and Dry Heat Shrinkage of Tow Throughput, g/min Winder Speed, m/m Dry Heat Shrinkage, % 14.06 750 1.4 14.06 1250 3.1 21.52 750 1.2 21.52 1250 2.3

Example 2 Undrawn Melt Spun Fiber Containing PTT and Co-PET

Polytrimethylene terephthalate containing 0.3% TiO₂ and having an intrinsic viscosity of 0.96 dL/g was melt blended with fiber-grade post-consumer recycled Co-PET containing 1.1 mol % IPA monomer, 49.1 mol % TPA monomer, and 49.9 mol % of EG monomer in a twin-screw extruder in a 50/50 weight ratio to form compounded pellets. The Co-PET had an intrinsic viscosity of 0.76 dL/g. Extruder throughput was 150 lb/h (0.0189 kg/s) and melt temperature at extruder exit was under 285° C. as measured by a hand-held thermocouple.

PTT:Co-PET compounded pellets were dried at 120° C. under nitrogen blanket in a vacuum oven for 16 hours and melt-extruded into round cross-section, 34-filament yarn bundle using a twin-screw extruder spinning machine. Extruder melt zone temperatures were maintained from 180-255° C. Polymer throughput was either 14.06 g/min or 21.52 g/min. For each throughput, winder speed was either 750 m/m or 1250 m/m giving a spun denier per filament from 3.3 to 7.7. Dry heat shrinkage of yarn bundles was measured to be in the range of 1.2% to 2.5%. This amount of dry heat shrinkage in undrawn fiber is very low and indicates stability of the material during storage. Results are shown in the following Table.

TABLE 2 Example 2 Spinning Conditions and Dry Heat Shrinkage of Tow Throughput, g/min Winder Speed, m/m Dry Heat Shrinkage, % 21.52 750 1.2 21.52 1250 3 14.06 750 1.2 14.06 1250 2.5

Example 3 Melt Spun Staple Fiber Containing PTT and Co-PET

Polytrimethylene terephthalate containing 0.3% TiO₂ and having an intrinsic viscosity of 0.96 dL/g was melt blended with Co-PET (from Nan Ya Plastics) in a twin-screw extruder in a 50/50 weight ratio to form compounded pellets. Extruder throughput was 150 lb/h (0.0189 kg/s) and melt temperature at extruder exit was under 285° C. as measured by a hand-held thermocouple. Compounded material was at 145° C. for 20 hours.

6800 Round cross-section filaments were spun using a single-extruder spinning machine with radial quench. Extruder melt zone temperatures were maintained from 252-274° C. Polymer throughput was 0.379 g/min/hole and feed roll speed was 1100 m/m. Spun dpf was 3.0. Spun fibers were collected in cans. Twenty-two cans, totaling 448,800 denier, fed draw-crimp-cut/bale module. A typical cotton count staple process utilizing multi-stage draw, crimper, annealer, and cutter was used to produce staple melt spun fiber. Tow was dipped in a finish bath (0.5% concentration, commercially available, Seilacher from Schill+Seilacher) at 22° C. Tow was first drawn, in a 0.5% concentration finish bath at 80° C. between a 22° C. feed roll running at 36 m/m and heated draw rolls at 75° C. running at 110.88 m/m giving a first stage draw ratio of 3.08. Drawn tow was pulled through a steam chest at 100° C. by a downstream heated roll at 165° C. and running at 110.88 m/m. Tow was passed over another set of rolls heated at 165° C. running at 99.8 m/m. Finish (6% concentration) was sprayed and tow was passed over cooling drum rolls at 25° C., running at 99.8 m/m. Tow entered a steam box at 100° C. prior to entering a 50-mm crimper. Crimper speed was 100 m/m. Crimper roller temperature and pressure was 65° C. and 0.8 bar, respectively. Crimped tow was annealed for 8 min at 100° C. in a plate belt drier, Crimped tow was finally cut to produce staple melt spun fiber having the following properties:

Denier per filament (dpf)=1.2, Coefficient of variation (CV)=8.79%

Tenacity=4.89 g/d, CV=8.79%

Elongation=45.97%, CV=19.59%

Staple length=37-38 mm

Number of crimp (full-sinus arc)=12/inch

Crimp stability=67.09%, CV=22.1%

Finish on yarn=0.26%

Example 4 Melt Spun Fiber Containing PTT and Co-PET

Polytrimethylene terephthalate containing 0.3% TiO2 and having an intrinsic viscosity of 0.96 dL/g was melt blended with Co-PET (from Nan Ya Plastics) in a twin-screw extruder in a 50/50 weight ratio to form compounded pellets. Extruder throughput was 150 lb/h (0.0189 kg/s) and melt temperature at extruder exit was under 285° C. as measured by a hand-held thermocouple. Compounded material was at 145° C. for 20 hours.

6800 Round cross-section filaments were spun using a single-extruder spinning machine with radial quench. Extruder melt zone temperatures were maintained from 252-274° C. Polymer throughput was 0.493 g/min/hole and feed roll speed was 600 m/m. Spun dpf was 7.2. Spun fibers were collected in cans. Ten cans, totaling 489,600 denier, fed draw-crimp-cut/bale module. A typical wool count staple process utilizing multi-stage draw, crimper, annealer and cutter was used to produce melt spun staple fiber. Tow was dipped in a finish bath (0.5% concentration, commercially available, Seilacher from Schill+Seilacher) at 22° C. Tow was first drawn in a 0.5% concentration finish bath at 80° C. between a 22° C. feed roll running at 30 m/m and heated draw rolls at 75° C. running at 109.3 m/m giving a first stage draw ratio of 3.64. Tow was pulled by a downstream heated roll at 165° C. and running at 103.9 m/m. Finish (6% concentration) was sprayed and tow was passed over cooling drum rolls at 25° C., running at 101.9 m/m. Tow entered a steam box at 100° C. prior to entering a 50-mm crimper. Crimper speed was 110.6 m/m. Crimper roller temperature and pressure was 65° C. and 1.3 bar, respectively. Crimped tow was annealed for 8 min at 100° C. in a plate belt drier, Crimped tow was finally cut to produce staple having the following properties:

dpf=2.5, CV=6.98%

Tenacity=3.83 g/d, CV=8.74%

Elongation=69.72%, CV=25.26%

Staple length=82-125 mm multi-cut length with an average of 84 mm

Number of crimp (full-sinus arc)=14/inch

Crimp stability=91.19%, CV=8.31%

Finish on yarn=0.21%

Commercially Obtained Spun Yarns

Table 3 lists commercially obtained spun yarns and the abbreviations used for them in the Tables which follow. Some of these yarns were used to prepare the fabrics of the Comparative Examples.

TABLE 3 Abbreviations for Spun Yarns Obtained Commercially. Cotton Count and Yarn Composition Abbreviation 20 s Ne 100% PET staple P1 40 s Ne 100% PET staple P2 20 s Ne 40/60 blended PET/cotton staple PC1 40 s Ne 40/60 blended PET/cotton staple PC2 20 s Ne 40/60 blended PET/Tencel ® staple PT1 40 s Ne 40/60 blended PET/Tencel ® staple PT2 20 s Ne 100% PTT staple P3 40 s Ne 100% PTT staple P4 20 s Ne 40/60 blended PTT/cotton staple PC3 40 s Ne 40/60 blended PTT/cotton staple PC4 20 s 40/60 blended PTT/Tencel ® staple PT3 40 s 40/60 blended PTT/Tencel ® staple PT4

Spun Yarn Examples Made on Cotton System

Melt spun staple fiber from Example 3 was used to prepare the spun yarns of Examples 5-10. The spun yarns, and the intermediate materials such as sliver obtained in the preparation of the spun yarns, were evaluated using the following methods:

Tenacity was measured at 5 m/min using CRE type tensile testing equipment (such as Uster Tensorapid −3) at jaw speed of 5 m/min and specimen length of 50 cm.

Breaking elongation %—measured using CRE type tensile testing equipment (such as Uster Tensorapid −3) at jaw speed of 5 m/min and specimen length of 50 cm.

Example 5 20s Ne Spun Yarn Containing 100% Melt Spun Fiber

Spun yarn was made using the cotton spinning system, according to the following procedure.

Melt spun staple fiber from Example 3 was taken from bales and hand mixed. The average staple fiber length was 40 mm and the denier was 1.2 D. The fibers were mixed and laid in layers in a stack mixing process, then conditioned at 65% relative humidity and 25° C. for 24 hours. Fiber mass was taken from the stack by vertically withdrawing material and feeding it to a blow room line as typically used to spin synthetic fibers. In this process, the size of a fiber tuft was broken down from about 150 mg to about 30 mg. The following parameters were used:

-   -   Feed rollers and beaters blades setting=1.7 mm     -   Lap linear density ˜400 g/meter     -   All waste collection setting is closed to ‘0’     -   Coarse opening beater speed=400 rpm     -   Fine opening beater speed=450 rpm

Next, the 30 mg fiber bunches were carded to single fibers and arranged into a continuous fiber strand (sliver) where fibers were oriented along the length of the sliver. The following parameters were used:

-   -   Machine type, Model : card frame, L R C 1/3     -   M/c Production speed=70 meter/min     -   Feed Plate and Licker in gauge=32 thou (thousandths of an inch)     -   Flat gauge=14,14,14,12,12 thou     -   Trumpet size=4.0 mm or above     -   Sliver linear density=4.5 g/meter     -   Licker in Speed=650 rpm     -   Cylinder Speed=350 rpm     -   Flat speed=6 inches/min     -   Final sliver linear density=5.0 g/meter

In a draw frame machine, six carding slivers were doubled together and simultaneously drafted by the same amount (6×) to further orient the fibers in the resultant sliver. The first step is referred to as breaker drawing and the second step is referred to as finisher drawing. The following parameters were used:

-   -   Machine type and model: Draw frame, L R RSB 851     -   Bottom Roller gauge Front/Back=44/48 mm     -   Trumpet diameter=3.8 mm     -   Sliver linear density=4.5 g/meter     -   Top cots hardness=83° degree     -   Break drafts =1.4 in breaker, 1.4 in finisher draw frame     -   Web tension draft=1     -   Creel tension draft=1.02     -   Delivery speed=250 MPM in I draw frame, 350 MPM in II draw frame     -   Doubling=6 for both I and II draw frame     -   Final sliver linear density=5.00 g/meter     -   Unevenness %=1.88 in finisher sliver

Next, roving was prepared from the sliver delivered from the final draw frame at a speed frame machine. Partial twist is also given in the speed frame in order to impart strength to the roving. The following parameters were used:

-   -   Machine type and Model : Speed Frame, LF 4200     -   Spacer size=5.5 mm     -   Spindle speed=1000 rpm     -   Twist multiplier=0.70     -   Roving Hank=0.75 s Ne     -   Roller Gauge=48/55/62 mm     -   Cradle=36 mm         The roving was found to have Uster value (unevenness) of 3.16%         and Uster % (unevenness %) of 3.26.

The roving was drafted further on a ring frame spinning machine to produce spun yarn having a yarn count of 20s Ne. The following parameters were used:

-   -   Machine Type and Model=Ring Frame, LR G 5/1     -   Roller gauge=42.5/65 mm     -   Saddle gauge =51/66 mm     -   Cots hardness (front/back F/B)=68/83°     -   Break draft=1.22     -   Twist multiplier/twist per inch=3.6/16.09     -   Traveler size: 1/0 M1HO     -   Spindle speed: 15500 rpm

The spun yarn was wound at ring frame on small packages called cops, each weighing about 50 g. Many cops were joined and cleared for any yarn defect, and finally wound into a cone on a winding machine using the following parameters:

-   -   Speed =1000 m/min     -   Yarn tension=5-6% of yarn breaking load     -   Package Hardness—minimum     -   Cone Weight=1.0 kg or more

The final spun yarn was evaluated for tensile properties and unevenness % on Uster tensorapid-3 and Uster unevenness tester-3. Results are shown in Table 4.

The yarn wound in the final machine was lively and could snarl as a result of twist imparted in the spinning process. As snarling can cause yarn breakage during fabric manufacturing, the yarn was rendered structurally stable by conditioning the cone in an autoclave at a maximum temperature of 70° C. for 50 minutes.

Example 6 40s Ne Spun Yarn Containing 100% Melt Spun Fiber

Spun yarn was prepared using melt spun staple fiber from Example 3 according to the procedure of Example 5 except with the following differences:

The linear density of the final sliver was 4.75 g/meter and the Unevenness % was 1.75

Roving was prepared as in Example 5 except that the roving hank was 1.2 s Ne.

In the step of drafting the roving, the twist multiplier/twist per inch was 3.6/22.6, the Traveler size was 4/0 M1HO, and the spindle speed was 16500 rpm.

The spun yarn was wound onto a cone at 1500 meters/min.

Properties of the spun yarn are given in Table 4.

Example 7 20s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Cotton (wt/wt)

Spun yarn was prepared using melt spun staple fiber from Example 3 and cotton (Shankar 6 variety Indian cotton obtained from north Indian states, for example Punjab and Haryana). The cotton staple had average length of 31 mm and fineness (fiber linear density) of 4.1 microgram/inch, measured using an airflow method. The spun yarn was made according to the procedure of Example 5 except with the following differences:

In the hand mixing step, two layers of cotton sliver, taken from 100% cotton yarn spinning process after the combing machine and broken into small tuft size of 25-30 mg, were laid over one layer of melt spun staple fiber.

The linear density of the final sliver from the carding step was 4.7 g/meter. Roving was prepared as in Example 5 except that the twist multiplier was 0.85 and the roving hank was 0.7 s Ne.

The roving was drafted further as in Example 5 except with twist per inch of 16.99.

Properties of the spun yarn are given in Table 4.

Example 8 40s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Cotton (wt/wt)

Spun yarn was prepared using melt spun staple fiber from Example 3 and cotton (Shankar 6 variety Indian cotton commercially obtained from north Indian states). The cotton staple had average length of 31 mm and linear density of 4.1 microgram/inch. The spun yarn was made according to the procedure of Example 5 except with the following differences:

In the hand mixing step, two layers of cotton sliver, taken from 100% cotton yarn spinning process after the combing machine and broken into small tuft size of 25-30 mg, were laid over one layer of melt spun staple fiber.

The linear density of the final sliver from the carding step was 4.7 g/meter.

After drawing, the final sliver linear density was 4.75 g/meter.

Roving was prepared as in Example 5 except that the twist multiplier was 0.85 and the roving hank was 1.2 s Ne.

The roving was drafted further as in Example 5 except with twist per inch of 24.02, traveler size 4/0 M1HO, and spindle speed 16500 rpm.

The spun yarn was wound onto a cone at 1500 meters/min.

Properties of the spun yarn are given in Table 4.

Example 9 20s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Tencel

Spun yarn was prepared using melt spun staple fiber from Example 3 and commercially-obtained Tencel® staple fiber (Lenzing).The Tencel® staple fiber had average length of 40 mm and denier of 1.2 D. The spun yarn was made according to the procedure of Example 5 except with the following differences:

In the hand mixing step, two layers of Tencel® fiber (broken into small tuft size of 25-30 mg) were laid over one layer of melt spun staple fiber.

The linear density of the final sliver from the carding step was 4.7 g/meter.

Roving was prepared as in Example 5 except that twist multiplier was 0.85.

The roving was drafted further as in Example 5 except with twist per inch of 16.99.

Properties of the spun yarn are given in Table 4.

Example 10 40s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Tencel

Spun yarn was prepared using melt spun staple fiber from Example 3 and commercially-obtained Tencel® staple fiber (Lenzing). The Tencel® staple had average length of 40 mm and denier of 1.2 D. The spun yarn was made according to the procedure of Example 5 except with the following differences:

In the hand mixing step, two layers of Tencel® fiber (broken into small tuft size of 25-30 mg) were laid over one layer of melt spun staple fiber.

The linear density of the final sliver from the carding step was 4.7 g/meter.

After drawing, the final sliver linear density was 4.75 g/meter.

Roving was prepared as in Example 5 except that twist multiplier was 0.85 and the roving hank was 1.2 s Ne. The roving was drafted further as in Example 5 except with twist per inch of 24.02, traveler size 4/0 M1HO, and spindle speed 16500 rpm.

The spun yarn was wound onto a cone at 1500 meters/min. Properties of the spun yarn are given in Table 4.

TABLE 4 Properties of the Spun Yarns of Example 5 Through Example 10 and of Comparative Spun Yarns Obtained Commercially Number of Ex. No. Breaking Imperfections or Tenacity² Elongation U (per km of Hairiness Yarn¹ Yarn Description (cN/Tex) (%) % yarn) Index  5 20s Ne 100% melt 24.1 26.3 8.5 9 6.60 spun staple P1 20s Ne 100% PET 35.5 14.7 8.4 30 7.79 P3 20s Ne 100% PTT 17.9 36.4 9.5 18 6.36  6 40s Ne 100% melt 22.8 21.5 11.5 74 4.81 spun staple P2 40s Ne 100% PET 30.3 9.6 11.7 118 6.06 P4 40s Ne 100% PTT 16.6 30.5 13.3 303 5.11  7 20s Ne 40/60 melt 13.9 6.6 10.0 78 7.17 spun staple/cotton PC1 20s Ne 40/60 18.7 7.4 9.3 20 6.58 PET/cotton PC3 20s Ne 40/60 10.8 7.3 10.5 70 7.43 PTT/cotton  8 40s Ne 40/60 melt 13.2 4.8 12.3 243 4.90 spun staple/cotton PC2 40s Ne 40/60 16.2 5.6 11.8 203 4.9 PET/cotton PC4 40s Ne 40/60 10.6 6.1 13.3 446 5.15 PTT/cotton  9 20s Ne 40/60 melt 17.7 8.3 8.4 16 8.12 spun staple/Tencel ® PT1 20s Ne 40/60 24.7 9.7 8.7 10 7.59 PET/Tencel ® PT3 20s Ne 40/60 15.7 8.3 9.0 10 7.73 PTT/Tencel ® 10 40s Ne 40/60 melt 13.9 5.0 12.1 156 6.04 spun staple/Tencel ® PT2 40s Ne 40/60 21.7 8.1 11.5 164 5.59 PET/Tencel ® PT4 40s Ne 40/60 13.3 5.8 11.2 166 5.80 PTT/Tencel ® Notes: ¹see Table 3 for abbreviations of spun yarns obtained commercially ²at 5 meter/min speed

The results in Table 4 show that the spun yarns comprising 100% melt spun staple fiber alone or in combination with cotton or Tencel®, have tenacity and breaking elongation sufficient for weaving or knitting processes.

Spun yarns (Examples 5 and 6) consisting of only the melt spun staple fiber of Example 3, poly(ethylene terephthalate) staple, or poly(trimethylene terephthalate) staple were subjected to a boiling water shrinkage test method according to ASTM D2259. The length of yarn skeins, with the indicated dead weight attached, were measured before and after being immersed in boiling water (100° C., 30 min in autoclave, MLR 1:40 where “MLR” means material to liquor ratio) and the difference in skein length divided by skein length before boiling is reported as % Shrinkage in Table 5. PET spun yarns and PTT spun yarn were obtained commercially.

TABLE 5 Boiling Water Shrinkage of Spun Yarns Boiling Initial Final Water Length Length Shrinkage, Yarn Count Yarn Sample (cm) (cm) % 40 s, dead Ex. 6 1 67.5 60.4 10.6 weight 1 kg 2 67.4 60.2 Average 67.4 60.3 PET 1 67.3 65.4 2.82 (P2)* 2 67.3 65.4 Average 67.3 65.4 PTT 1 67.9 64.6 4.87 (P4)* 2 67.7 64.6 Average 67.8 64.5 20 s, dead Ex. 5 1 67.5 60.9 9.93 weight 2 kg 2 67.5 60.7 Average 67.5 60.8 PET 1 67.4 65.8 2.37 (P1)* 2 67.4 65.8 Average 67.4 65.8 PTT 1 68.1 64.3 5.44 (P3)* 2 68 64.4 Average 68 64.3 *Abbreviations are defined in Table 3.

Highest % boiling water shrinkage was observed for the spun yarn of Example 6 containing only melt spun staple fiber, with the lowest boiling water shrinkage observed for the spun yarns comprising PET and intermediate % shrinkage values observed for the spun yarns comprising PTT. This gives more fabric bulk after finishing for the melt spun staple fiber-based fabrics, which is desirable.

Woven Fabric Examples

Fabrics were evaluated using the following methods:

Fabric weight (greige and finished)—ASTM D3776 Standard Test Methods for Mass Per Unit Area (Weight) of Fabric

Dimensional stability (for both warp and weft directions, after 3 washes)—AATCC 135 Dimensional Changes of Fabrics After Home laundering

Wicking—AATCC 197 Vertical Wicking of Textiles

Tear Strength (for both warp and weft directions)—ASTM D1424 Standard Test Method for Tearing Strength of Fabrics by Falling Pendulum (Elmendorf-Type) Apparatus

Thickness—ASTM D1777 Standard Test Method for Thickness of Textile Materials

Pill rating (1000 rounds)—ASTM D4970 Standard Test Method for Pilling Resistance and Other Related Surface Changes of Textile Fabrics: Martindale Tester

Abrasion (5000 rounds)—ASTM D4966 Standard Test Method for Abrasion Resistance of Textile Fabrics (Martindale Abrasion Tester Method)

Drape—BS 5058 Method for the Assessment of Drape of Fabrics

Colorfastness to rubbing—AATCC 8 Colorfastness to Crocking

Colorfastness to washing—AATCC 61-2A (49° C., 45 min, 1.5 gpl)

Bursting Strength (circular knits)—ASTM D3786 Standard Test Method for Bursting Strength of Textile Fabrics

Stretch and Recovery (circular knits)—BS 4294 (5 kg) Methods of Test for the Stretch and Recovery Properties of Fabrics

Shrinkage % (in fabric, greige to finished) was determined as follows.

Greige fabric was marked with a permanent marker to indicate a 30 cm line in the fabric length (warp direction) and a 30 cm line in the fabric width (weft direction). The fabric was then dyed and finished, and the lengths of the permanent marker lines were remeasured. For each of the length (warp) and width (weft) directions, percent shrinkage was calculated by dividing the difference in length of the line before and after dyeing and finishing by 30 and multiplying by 100. This method is referred to herein as the Percent Shrinkage Method.

Softness assessment (also referred to as subjective Hand Value)—The subjective hand value assessment was done by assessing the feel of the fabric by 12 experts in the field, tested in South India Textile Research Association (SITRA), Coimbatore, India. This is the method widely used in Textile Industry for assessment of softness of fabrics. Fabrics were coded A and B and given to assess the ranking of fabric based on the perception of Fabric softness independently. The Softer fabric was ranked ‘1’ where as less soft fabric was ranked ‘2’ by each expert. This was done for 100% PET fabrics and the fabrics of Examples 11 and 14. Final ranking was done by averaging the 12 readings. The fabric with lower rank average was given final rank as 1 (softer) and fabric with higher rank average was given as rank 2.

The spun yarns of Examples 5 through 10 were used to make woven fabrics as indicated in Table 6. Woven twill (3/1) bottom weight fabrics and plain weave (1/1) shirting fabrics were made using the spun yarns disclosed herein as the warp and weft (fill) yarns; comparison fabrics were made using spun yarns obtained commercially in the warp and weft. For each woven fabric, the same yarn was used in both the warp and the weft. Fabric evaluation results are presented in Tables 7 and 8. Results are reported for finished fabric unless otherwise noted.

Example 11

Spun yarn from Example 5 was used as the warp and as the weft to prepare a bottom weight woven twill fabric. The warp yarns were sized before beaming using a CCI single end sizing machine using Elvanol-T25 PVA sizing agent. Using a warper at 350 m/min, a final beam with 2150 ends, a width of 18 inches, and end lengths of 3.5 meters was prepared. With the following denting plan:

Drawing: 4 shafts

Drawing type (straight drawing (1, 2, 3, &4)

Denting: 2 ends/dent

Reed count: 75 dents/2 inch

3/1 LHT twill fabric was woven on a CCI sample loom with loom speed at 40 picks/minute. The pick value was set at 63 picks/inch. Greige fabric of 2 m length and 49.5 cm width was obtained.

The greige fabric was desized on an RBE lab Jigger machine as follows. The fabric sample was loaded into the jigger filled with water (2 L), NaOH (2 gpl), and wetting agent; Levocol CESR (wetting agent) was added (5 gpl) and the bath temperature was raised to 90° C. The fabric was run in the bath for 60 mins, then the bath was drained, refilled with fresh water, and the temperature of the bath was raised to 85° C. The fabric was hot water washed for 15 min, and the bath was drained. The bath was again filled with water and the fabric was run through it for 15 min (cold water wash). Bath was drained, filled with water, and neutralized by adding acetic acid (1 gpl); fabric was run for 15 min in this bath. Afterwards, the bath was drained, refilled with fresh water, and the fabric run in cold water bath for 15 min. The fabric was then unloaded from the jigger and dryed in atmospheric conditions, then heat set in an RBE stenter at 160° C. for 45 seconds.

The fabric was then dyed with a mixture of disperse dyes using the following time and temperature profile: heat to 70° C. and hold for 10 minutes, then raise temperature 1.5° C./min to 130° C. and hold for 30 minutes, then decrease temperature 1.5° C/.min to 70° C. and drain. Post dyeing, the fabric was given a reduction cleaning with Hydros and NaOH (2 gpl each), 90° C. for 20 min. The fabric was then washed with cold water for 10 minutes, contacted with acetic acid (2 gpl) for 15 minutes, then washed with cold water for 10 minutes. The dyed fabric was padded with finishing agent (softener), then heat set at 160° C. for 45 seconds in an RBE lab stenter.

Fabric construction is shown in Table 6. Wicking test results were 100%. In comparison to the fabric of Comparative Example B, the fabric of Example 11 was found to have a softer hand (i.e. better softness). Other fabric properties are presented in Tables 7 and 8.

Comparative Example B

A comparative bottom weight woven 3/1 LHT twill fabric was made using commercially available 20s Ne 100% PET staple spun yarn (“P1”) as the warp and as the weft, following the procedure of Example 11 except that the denting plan used 4 ends/dent and the reed count was 50 dents/2 inch. The greige fabric was dyed, finished, and heat set as for Example 11.

Fabric construction is shown in Table 6. Wicking test results were 100%. Other fabric properties are presented in Tables 7 and 8.

Example 12

Spun yarn from Example 7 was used as the warp and as the weft to prepare a bottom weight woven twill fabric according to the procedure of Example 11 but with the following exceptions. The greige fabric was desized and bleached in a Jigger machine, heat set in a stenter, then dyed with a mixture of disperse dyes, then additionally dyed with a reactive dye under cotton dyeing conditions.

Fabric construction is shown in Table 6. Wicking test results were 100%. Other fabric properties are presented in Tables 7 and 8.

Comparative Example C

A comparative bottom weight woven 3/1 LHT twill fabric was made as in Example 12 except using commercially available 20s Ne 40/60 PET/cotton staple spun yarn (“PC1”) as the warp and as the weft.

Fabric construction is shown in Table 6. Wicking test results were 100%. Other fabric properties are presented in Tables 7 and 8.

Example 13

Spun yarn from Example 9 was used as the warp and as the weft to prepare a bottom weight woven twill fabric according to the procedure of Example 12, except that no peroxide killer was used at the end of the bleaching step.

Fabric construction is shown in Table 6. Wicking test results were 100%. Other fabric properties are presented in Tables 7 and 8.

Comparative Example D

A comparative bottom weight woven 3/1 LHT twill fabric was made following the procedure of Example 12 except using commercially available 20s Ne 40/60 PET/Tencel® staple spun yarn (“PT1”) as the warp and as the weft. The greige fabric was dyed, finished, and heat set as for Example 12 except that the second dyeing step, with a reactive dye, was done under Tencel® dyeing conditions.

Fabric construction is shown in Table 6. Wicking test results were 100%. Other fabric properties are presented in Tables 7 and 8.

Example 14

Spun yarn from Example 6 was used as the warp and as the weft to prepare a plain weave shirting fabric. The procedure was as described for Example 11 but with the following differences: after warping, the beam contained 1680 ends, and the reed count was 84 dents/2 inch.

Fabric construction is shown in Table 6. Wicking test results were 100%. In comparison to the fabric of Comparative Example E, the fabric of Example 14 was found to have a better (softer) hand. Other fabric properties are presented in Tables 7 and 8.

Comparative Example E

A comparative plain weave shirting fabric was made following the procedure of Example 11 except using commercially available 40s Ne 100% PET staple spun yarn (“P2”) as the warp and as the weft. After warping, the beam contained 1680 ends, and the reed count was 84 dents/2 inch. Greige fabric of 2 m length and 47.7 cm was obtained.

Fabric construction is shown in Table 6. Wicking test results were 100%. Other fabric properties are presented in Tables 7 and 8.

Example 15

Spun yarn from Example 8 was used as the warp and as the weft to prepare a plain weave shirting fabric. The procedure was as described for Example 12, except that no peroxide killer was used at the end of the bleaching step.

Fabric construction is shown in Table 6. Wicking test results were 100%. Other fabric properties are presented in Tables 7 and 8.

Comparative Example F

A comparative plain weave shirting fabric was made following the procedure of Example 11 except using commercially available 40s Ne 40/60 PET/cotton staple spun yarn (“PC2”) as the warp and as the weft and with the following additional differences in procedure: after warping, the beam contained 1748 ends, and the reed count was 92 dents/2 inch. Greige fabric of 2 m length and 48.7 cm width was obtained, and was dyed as described in Example 12.

Fabric construction is shown in Table 6. Wicking test results were 100%. Other fabric properties are presented in Tables 7 and 8.

Example 16

Spun yarn from Example 10 was used as the warp and as the weft to prepare a plain weave shirting fabric. The procedure was as described for Example Wfab-1, except that after warping the beam contained 1748 ends, the reed count was 92 dents/2 inch, and the pick value was set at 62 picks/inch. Greige fabric of 2 m length and 48.7 cm width was obtained, and was dyed as described in Example 12.

Fabric construction is shown in Table 6. Wicking test results were 100%. Other fabric properties are presented in Tables 7 and 8.

Comparative Example G

A comparative shirting fabric was made following the procedure of Example 11 except using commercially available 40s Ne 40/60 PET/Tencel® staple spun yarn (“PT2”) as the warp and as the weft and with the following additional differences in procedure: after warping, the beam contained 1748 ends, the reed count was 92 dents/2 inch, and the pick value was set at 62 picks/inch. Greige fabric of 2 m length and 48.7 cm width was obtained and dyed as described in Example 12.

Fabric construction is shown in Table 6. Wicking test results were 100%. Other fabric properties are presented in Tables 7 and 8.

TABLE 6 Woven Fabric Construction Warp and Weft Fabric Construction Fabric Weight Yarn (ends/inch * pick/inch) (g/m²) Ex. Count Yarn Fabric Details Fiber Blend % in Fabric Greige Finished Greige Finished 11 20s Ex 5 Bottom Weight, 100% melt spun staple 108*70 130*92 242 250 3/1 LHT Comp. 20s P1 Bottom Weight, 100% PET staple 108*70 114*80 222 230 Ex. B 3/1 LHT 12 20s Ex 7 Bottom Weight, 40/60 melt spun staple/ 108*70 128*88 248 288 3/1 LHT cotton Comp. 20s PC1 Bottom Weight, 40/60 PET/cotton 108*70 124*82 238 258 Ex. C 3/1 LHT 14 20s Ex 9 Bottom Weight, 40/60 melt spun 108*70 128*88 240 304 3/1 LHT staple/Tencel ® Comp. 20s PT1 Bottom Weight, 40/60 PET/Tencel ® 108*70 122*80 225 260 Ex. D 3/1 LHT 14 40s Ex 6 Shirting, plain 100% melt spun staple  96*66 120*88 115 142 Comp. 40s P2 Shirting, plain 100% PET staple  96*66 104*72 104 118 Ex. E 15 40s Ex 8 Shirting, plain 40/60 melt spun staple/  96*66 120*88 114 149 cotton Comp. 40s PC2 Shirting, plain 40/60 PET/cotton 104*66 116*76 117 127 Ex. F 16 40s Ex Shirting, plain 40/60 melt spun  96*66 116*82 107 137 10 staple/Tencel ® Comp. 40s PT2 Shirting, plain 40/60 PET/Tencel ®  96*66 104*74 100 107 Ex. G

TABLE 7 Woven Fabric Evaluation Results (First Half) Dimensional Tensile Breaking Tear Stability Strength Elongation Strength Thick- (%) (kgf) (%) (g) ness Ex. Warp Weft Warp Weft Warp Weft Warp Weft (mm) 11 −1.9 −1.3 28.6 28.6 47.5 47.4 >6400 5056 0.55 Comp. −2.7 −1.8 29.8 32.3 17.2 23.6 >6400 >6400 0.36 Ex. B 12 −1.5 −1.9 32.1 29.3 27.2 20.9 3008 1920 0.62 Comp. −2.6 −2.0 30.8 29.9 15.6 10.0 2880 3008 0.52 Ex. C 14 −2.1 −1.9 26.2 22.8 35.0 17.0 2752 2368 0.58 Comp. −1.2 −1.8 25.1 27.6 16.8 10.3 5376 4864 0.45 Ex. D 14 −1.9 −2.1 30.8 26.5 58.5 40.7 4416 2624 0.34 Comp. −2.2 −2.3 27.4 27.6 20.6 14.9 2944 2496 0.17 Ex. E 15 −1.6 −1.8 18.7 13.2 27.3 19.8 1280 896 0.34 Comp. −1.5 −1.7 12.9 12.4 7.7 7.6 1408 1408 0.22 Ex. F 16 −1.9 −1.6 20.2 16.2 20.6 12.5 1792 1472 0.32 Comp. −1.4 −1.5 25.8 14.5 11.4 5.7 2176 1984 0.19 Ex. G

TABLE 8 Woven Fabric Evaluation Results (Second Half) Shrinkage, Abrasion Drape Greige to Weight Area of Drape Finishing Colorfastness Colorfastness to Washing Pill loss Drape Coeff. Warp Weft to Rubbing Shade Ex. Rating Rating (%) (cm²) (%) (%) (%) Dry Wet Change Acetate Cotton Nylon PET Acrylic Wool 11 2-3 3-2 0.28 358.9 64.1 8.1 14.2 4-5 4 4-5 4 4 4 4-5 4-5 4-5 Comp. 1 1 0.55 221.2 26.7 3.2 3.8 4-5 3-4 4-5 3-4 4 3 4 4-5 4-5 Ex. B 12 4-5 4-5 0.9 341.9 59.5 9.7 12.7 4-5 4 4-5 4-5 4 3-4 4-5 4-5 4-5 Comp. 2 2-3 2.02 267.5 39.3 3.1 6.3 4-5 4 4-5 4-5 4 4 4-5 4-5 4-5 Ex. C 13 4-5 3-4 2.25 187.1 17.4 7.4 12.3 4-5 4 4-5 4 4 3-4 4 4-5 4-5 Comp. 2 1 2.74 177.1 14.7 3.5 5.3 4-5 3-4 4-5 4 4 3-4 4 4-5 4-5 Ex. D 14 3 2 0.3 317.0 52.7 7.9 16.3 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Comp. 1 1 1.66 202.3 21.5 1.2 4.6 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Ex. E 15 4-5 4-5 3.8 291.8 45.9 9.1 11.3 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Comp. 1 1-2 6.7 182.0 16.1 2.5 4.2 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Ex. F 16 3-4 2-3 4.37 176.7 14.6 8.0 9.7 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Comp. 3 1-2 7.37 163.4 11.0 2.3 4.8 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Ex. G

The results in the preceding Tables demonstrate that the fabrics containing the spun yarns disclosed herein provide a number of advantages over the fabrics of the Comparative Examples. Woven fabrics containing the spun yarns disclosed herein can have greater bulk, as indicated by the greater thickness of the fabrics of the Examples in comparison to Comparative Example fabrics of similar construction. The woven fabrics of the Examples also demonstrate less pilling (higher pill rating values), better abrasion resistance (lower % weight loss), and better drape (higher drape coefficient values) versus the fabrics of the Comparative Examples. Additionally, fabrics of the Examples can also dye more deeply (lower L* values with a D65 light source). The combination of improved hand (softer feel) and better drape is particularly desirable for fabrics.

Circular Knit Fabric Examples

The spun yarns of Examples 5 through 10 were used as the knitting yarn to make circular knit fabrics as indicated in Table 9; comparison fabrics were made using spun yarns obtained commercially. For all circular knit fabrics made using 20s Ne count yarns, the machine gauge was 20″. For all circular knit fabrics made using 40s Ne count yarns, the machine gauge was 24″. Fabric evaluation results are presented in Tables 9 and 10. Results are reported for finished fabric unless otherwise noted.

Example 17

Spun yarn from Example 5 was used to prepare a circular knit fabric on a Mesdan lab knitter. The greige fabric was heat set in an RBE stenter at 160° C. for 45 seconds, then scoured in an HTHP Beaker dyeing machine using the following procedure. The fabric was scoured at 90° C. for 60 minutes with NaOH (2 gpl) and wetting agent Levocol CESR (5 gpl) added. The fabric was washed at 85° C. for 15 minutes, then with cold water for 15 minutes, then with a neutralization solution containing acetic acid (1 gpl) for 15 minutes, followed by another cold water wash for 15 minutes.

The scoured fabric was then dyed in the same machine with a mixture of disperse dyes using the following time and temperature profile: heat to 70° C. and hold for 10 minutes, then raise temperature 1.5° C./min to 130° C. and hold for 30 minutes, then decrease temperature 1.5° C./min to 70° C. and drain. Post dyeing, the fabric was given a reduction cleaning with Hydros and NaOH (2 gpl each), 90° C. for 20 min. The fabric was then washed with cold water for 10 minutes, neutralized with acetic acid (2 gpl) for 15 minutes, then washed again with cold water for 10 minutes. The dyed fabric was padded with finishing agent (softener), then heat set at 160° C. for 45 seconds in a lab stenter.

Fabric construction is shown in Table 9. Wicking test results were 100%. In comparison to the fabric of Comparative Example H, the fabric of Example 17 was found to have a softer hand (i.e. better softness). Other fabric properties are presented in Tables 9 and 10.

Comparative Example H

A comparative knit fabric was made using following the procedure of Example 17 except that commercially available 20s Ne 100% PET staple spun yarn (“P1”) was used.

Fabric construction is shown in Table 9. Wicking test results were 100%. Other fabric properties are presented in Tables 9 and 10.

Example 18

Spun yarn from Example 7 was used to prepare a circular knit fabric on a Mesdan lab knitter following the procedure of Example 17, except that after dyeing with the disperse dyes, the fabric was dyed in the same machine with a reactive dye mixture to which salt (60 gpl) was added, using the following time and temperature profile: heat to 60° C. and hold for 30 minutes, then add soda ash (15 gpl) and hold for 30 minutes before draining. The fabric was then washed with cold water for 10 minutes, washed with acetic acid (1 gpl) for 15 minutes, then given a hot soaping with Albatex AD (2 gpl) during which the temperature was raised to 90° C. and held for 15 minutes. The fabric was then washed with hot water (85° C.) for 15 minutes, and then with cold water for 10 minutes. The dye was fixed with Levocol HCF (0.5 gpl) during which the temperature was raised to 50° C. and held for 20 minutes. The dyed fabric was padded with finishing agent then heat set at 160° C. for 45 seconds in a lab stenter.

Fabric construction is shown in Table 9. Wicking test results were 100%. Other fabric properties are presented in Tables 9 and 10.

Comparative Example I

A comparative knit fabric was made using following the procedure of Example 18 except that commercially available 20s Ne 40/60 PET/cotton staple spun yarn (“PC1”) was used.

Fabric construction is shown in Table 9. Wicking test results were 100%. Other fabric properties are presented in Tables 9 and 10.

Example 19

Spun yarn from Example 9 was used to prepare a circular knit fabric on a Mesdan lab knitter following the procedure of Example 18.

Fabric construction is shown in Table 9. Wicking test results were 100%. Other fabric properties are presented in Tables 9 and 10.

Comparative Example J

A comparative knit fabric was made using following the procedure of Example 18 except that commercially available 20s Ne 40/60 PET/Tencel® staple spun yarn (“PT1”) was used.

Fabric construction is shown in Table 9. Wicking test results were 100%. Other fabric properties are presented in Tables 9 and 10.

Example 20

Spun yarn from Example 6 was used to prepare a circular knit fabric on a Mesdan lab knitter following the procedure of Example 1 except that a different mixture of disperse dyes was used.

Fabric construction is shown in Table 9. Wicking test results were 100%. In comparison to the fabric of Comparative Example K, the fabric of Example 20 was found to have a better hand (i.e. better softness). Other fabric properties are presented in Tables 9 and 10.

Comparative Example K

A comparative knit fabric was made using following the procedure of Example 17 except that commercially available 40s Ne 100% PET staple spun yarn (“P2”) and a different mixture of disperse dyes were used.

Fabric construction is shown in Table 9. Wicking test results were 100%. Other fabric properties are presented in Tables 9 and 10.

Example 21

Spun yarn from Example 8 was used to prepare a circular knit fabric on a Mesdan lab knitter following the procedure of Example 18, except that a different mixture of disperse dyes was used.

Fabric construction is shown in Table 9. Wicking test results were 100%. Other fabric properties are presented in Tables 9 and 10.

Comparative Example L

A comparative knit fabric was made using following the procedure of Example 18 except that commercially available 40s Ne 40/60 PET/cotton staple spun yarn (“PC2”), a different mixture of disperse dyes, and a different mixture of reactive dyes used were used.

Fabric construction is shown in Table 9. Wicking test results were 100%. Other fabric properties are presented in Tables 9 and 10.

Example 22

Spun yarn from Example 10 was used to prepare a circular knit fabric on a Mesdan lab knitter following the procedure of Example 18, except with a different mixture of disperse dyes and a different mixture of reactive dyes.

Fabric construction is shown in Table 9. Wicking test results were 100%. Other fabric properties are presented in Tables 9 and 10.

Comparative Example M

A comparative knit fabric was made using following the procedure of Example 18 except that commercially available 40s Ne 40/60 PET/Tencel® staple spun yarn (“PT2”), a different mixture of disperse dyes, and a different reactive dye were used.

Fabric construction is shown in Table 9. Wicking test results were 100%. Other fabric properties are presented in Tables 9 and 10.

TABLE 9 Circular Knit (CK) Fabric Construction and Evaluation Results Dimensional Abrasion Yarn Fabric Weight Stability Bursting Weight Count Fiber Blend % in (g/m²) Length Width Strength Pill Loss Thickness Ex. (Ne) Yarn CK fabric Greige Finished (%) (%) (kg/cm²) Rating Grade (%) (mm) 17 20s Ex 5 100% melt 165 258 −1.4 −2.8 9.2 3-4 3-4 0.16 0.55 spun staple Comp. 20s P1 100% PET 156 188 −1.1 −2.5 12.7 1-2 1 0.97 0.41 Ex. H staple 18 20s Ex 7 40/60 melt 166 248 −2.9 −2.2 6.4 3 3-4 0.48 0.7 spun staple/ cotton Comp. 20s PC1 40/60 172 182 −2.7 −2.4 7.3 1-2 1-2 1.73 0.51 Ex. I PET/cotton 19 20s Ex 9 40/60 melt 180 253 −1.7 −1.9 6.8 4-5 2 3.94 0.62 spun staple/Tencel ® Comp. 20s PT1 40/60 167 197 −2.0 −1.5 7.5 1-2 1-2 6.07 0.48 Ex. J PET/Tencel ® 20 40s Ex 6 100% melt 107 161 −2.6 −1.8 7.2 2-3 1-2 0.13 0.46 spun staple Comp. 40s P2 100% PET 100 124 −1.7 −1.3 8.7 1 1 0.94 0.31 Ex. K staple 21 40s Ex 8 40/60 melt 108 153 −1.6 −2.7 5.8 4 3-4 0.68 0.52 spun staple/ cotton Comp. 40s PC2 40/60 102 117 −2.4 −2.8 5.9 1-2 1 1.69 0.35 Ex. L PET/cotton 22 40s Ex 10 40/60 melt spun 101 130 −1.8 −2.1 4.9 3-4 2 6.21 0.42 staple/Tencel ® Comp. 40s PT2 40/60 101 130 −2.0 −2.4 5.3 1-2 1 7.36 0.3 Ex. M PET/Tencel ®

TABLE 10 Circular Knit (CK) Fabric Evaluation Results Continued Stretch & Recovery (%) 30 60 30 60 Length 1 min min min Width 1 min min min Colorfastness Colorfastness to Washing Stretch recov recov recov stretch recov recov recov to Rubbing Shade Ex. (%) (%) (%) (%) (%) (%) (%) (%) Dry Wet change Acetate Cotton Nylon PET Acrylic Wool 17 36.0 91.3 94.2 97.1 67.0 96.9 98.4 98.4 4-5 4-5 4-5 4-5 4-5 4 4 4 4-5 Comp. 40.0 63.3 68.8 71.8 80.0 62.3 66.6 68.8 4-5 4 4-5 4 4 3-4 4 4 4-5 Ex. H 18 51.0 83.5 83.5 87.6 82.0 83.3 89.7 91.0 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Comp. 50.0 73.8 74.4 75.6 84.0 73.2 73.8 74.4 4-5 3-4 4-5 4-5 4-5 3-4 4-5 4-5 4-5 Ex. I 19 52.0 89.9 93.9 93.9 86.0 86.5 90.2 90.2 4-5 4 4-5 4-5 4-5 4 4-5 4-5 4-5 Comp. 63.0 74.8 76.2 77.5 90.0 73.8 75.4 76.7 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Ex. J 20 38.0 91.7 94.5 94.5 95.0 92.3 96.7 97.8 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Comp. 43.0 75.4 77.0 79.5 104.0 74.5 77.8 79.3 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Ex. K 21 55.0 82.8 84.7 85.5 115.0 87.0 87.7 88.2 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Comp. 58.0 73.6 75.0 76.4 120.0 75.3 76.7 78.3 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Ex. L 22 65.0 80.6 87.0 88.7 150.0 80.6 82.2 84.9 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Comp. 55.0 72.7 75.1 76.4 145.0 74.1 75.5 77.1 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Ex. M

The results in Tables 9 and 10 demonstrate that the circular knit fabrics of the Examples provide advantages over the fabrics of the Comparative Examples. For example, the circular knit fabrics containing spun yarns comprising the melt spun staple fibers disclosed herein have greater bulk in comparison to the fabrics of the Comparative Examples, as shown by the greater thickness of the fabrics. The circular knit fabrics of the Examples also demonstrate less pilling (higher pill rating values) and better abrasion resistance (lower % weight loss). Additionally, the fabrics of the Examples have better stretch recovery than the Comparative Example fabrics, both at shorter and longer recovery times.

Example 23 2/64s Nm Spun Yarn Containing 70/30 Wool/Melt Spun Staple Fiber

Spun yarn was made using the worsted spinning system, according to the following procedure.

Melt spun staple fiber from Example 4 was used to prepare the spun yarn of Example 23. The melt spun staple fiber, 2.5 denier and of 84 mm average length, was taken and converted to sliver in cotton card spinning system as per regular process of carding normally used in spinning mills. This sliver was blended with wool top (Australian Merino of 20.5 micron, 68 mm average mean length) and spun in worsted spinning system in 70/30 (wt/wt) wool/melt spun staple fiber blend proportion. The nominal count spun for the spun yarn was 2/64s Nm.

Example 24

Spun yarn from Example 23 was used as the warp and as the weft to prepare a bottom weight twill fabric. The warp yarns were sized before beaming using a CCI single end sizing machine using Elvanol-T25 PVA sizing agent and a softener. Using a warper at 350 m/min, a final beam with 1770 ends, a width of 18 inches, and end lengths of 3.5 meters was prepared. With the following denting plan:

Drawing: 3 shafts

Drawing type (straight drawing (1, 2, &3))

Denting: 3 ends/dent

Reed count: 60 dents/2 inch

2/1 RHT twill fabric was woven on a CCI sample loom with loom speed at 40 picks/minute. The pick value was set at 63 picks/inch. Greige fabric of 2 m length and 50 cm width was obtained.

The greige fabric was desized in a Jigger machine using a procedure similar to that of Example 11, except that Albatex AD was used in conjunction with Levocol CESR. The fabric was then subjected to a hot water wash (85° C. for 15 minutes), a cold water wash (15 minutes), a neutralization step with acetic acid (15 minutes), and another cold water wash (15 minutes). The fabric was allowed to dry flat in atmospheric conditions, then heat set at 170° C. for 45 seconds.

The fabric was then dyed with a mixture of disperse dyes using the following time and temperature profile: heat to 70° C. and hold for 10 minutes, then raise temperature 1.5° C./min to 130° C. and hold for 30 minutes, then decrease temperature 1.5° C./min to 70° C. and drain. The fabric was given a reduction cleaning with Hydros and NaOH (1 gpl each), 90° C. for 20 min. The fabric was then washed with cold water for 10 minutes, contacted with acetic acid (2 gpl) for 15 minutes, then washed with cold water for 10 minutes.

The fabric was then dyed with a mixture of acid dyes using the following time and temperature profile: heat to 70° C. and hold for 10 minutes, then raise temperature 1.5° C./min to 98° C. and hold for 45 minutes, then decrease temperature 1.5° C./min to 70° C. and drain. The fabric was washed in cold water (10 minutes), treated with acetic acid (1 gpl for 15 minutes), subjected to a hot soaping with Albatex AD (90° C. for 15 minutes), washed with hot water (85° C. for 15 minutes), washed with cold water (10 minutes), then contacted with Levocol HCF (0.5 gpl) at 50° C. for 20 minutes to fix the dye.

The fabric was decatized in an autoclave (130° C. for 3 minutes) then padded with finishing agent before being heat set at 160° C. for 45 seconds in a lab stenter, and then decatized again in an autoclave (130° C. for 3 minutes). The greige and finished fabrics were evaluated. Results are as follows:

Greige fabric construction: 96*54 (end/inch*pick/inch)

Finished fabric construction: 114*63 (end/inch*pick/inch)

Greige fabric weight: 198 g/m²

Finished fabric weight: 249 g/m²

Dimensional stability (%):

-   -   Length −2.8%;     -   Width −1.7%

Wicking test: 100%

Tear strength: warp 1984 g, weft 896 g

Stretch %: 42.7

Recovery at 1 minute, %: 83.1

Recovery at 30 minutes, %: 90.9

Recovery at 60 minutes, %: 93.51

Example 25 Undrawn Melt Spun Fiber Containing PTT and Co-PET

Pellets of polytrimethylene terephthalate (PTT) containing 0.3% TiO₂ and having an intrinsic viscosity of 0.96 dL/g and pellets of polyethylene terephthalate co-ethylene isophthalate (Co-PET) (from Nan Ya Plastics) having an intrinsic viscosity of 0.80 dL/g were dried separately at 120° C. under nitrogen blanket in a vacuum oven for 16 hours. Dried pellets of PTT and dried pellets of Co-PET were blended together in a small drum by hand shaking and rolling actions of the drum in the ratios give in Table 11. Each of the salt-and-pepper blends thus created was melt-extruded into round cross-section, 34-filament yarn bundle using a twin-screw extruder spinning machine. Extruder melt zone temperatures were maintained from 180-265° C. Polymer throughput, winder speed, spun denier per filament, and dry heat shrinkage of yarn bundles (tow) are provided in Table 11.

TABLE 11 Example 25 Spinning Conditions and Dry Heat Shrinkage of Tow Winder Dry Heat PTT, Co-PET, Throughput, Speed, Shrinkage, % % g/min m/m % 90 10 21.52 1250 21.5 80 20 21.52 1250 5 70 30 21.52 1250 3.9 50 50 21.52 1250 2.1 30 70 21.52 1250 2.1 20 80 21.52 1250 1.7 10 90 21.52 1250 1.7

Example 26 Undrawn Melt Spun Fiber Containing Co-PET and PBT

Pellets of polyethylene terephthalate co-ethylene isophthalate (Co-PET) (from Nan Ya Plastics) having an intrinsic viscosity of 0.80 dL/g and pellets of CRASTIN® 6130C NC010 polybutylene terephthalate (PBT) having an intrinsic viscosity of 1.15 dL/g were dried separately at 120° C. under nitrogen blanket in a vacuum oven for 16 hours. The dried pellets of PTT and PBT were blended together in a small drum by hand shaking and rolling actions of the drum in the ratios give in Table 12. Each of the salt-and-pepper blends thus created was melt-extruded into round cross-section, 34-filament yarn bundle using a twin-screw extruder spinning machine. Extruder melt zone temperatures were maintained from 180-265° C. Polymer throughput, winder speed, spun denier per filament and dry heat shrinkage of yarn bundles (tow) are provided in Table 12.

TABLE 12 Example 26 Spinning Conditions and Dry Heat Shrinkage of Tow Winder Dry Heat PBT, Co-PET, Throughput, Speed, Shrinkage, % % g/min m/m % 90 10 21.52 1250 2.6 80 20 21.52 1250 3.1 70 30 21.52 1250 3.4 50 50 21.52 1250 3.8 30 70 21.52 1250 2.2 20 80 21.52 1250 2.1 10 90 21.52 1250 1.4

Example 27 Melt Spun Staple Fiber Containing Salt-and-Pepper Blends of 20 wt % PTT and 80 wt % Co-PET

A single-screw extruder was used to co-feed polytrimethylene terephthalate and co-PET (from Nan Ya Plastics) a 7590-hole spinneret in 20:80 weight ratio. Polytrimethylene terephthalate contained 0.3% TiO₂ and had an intrinsic viscosity of 0.96 dL/g. Round cross-section filaments were spun at an extruder throughput of 100 kg/h using radial quench. Extruder melt zone temperatures were maintained from 252-263° C. Polymer throughput was 0.220 g/min/hole and feed roll speed was 650 m/m. Spun dpf was nominally 3.4. Spun fibers were collected in cans.

Sixteen (16) cans, totaling 412,896 denier, fed draw-crimp-cut/bale module. A typical cotton count staple process utilizing multi-stage draw, crimper, annealer, and cutter was used to produce staple melt spun fiber. Tow was dipped in a finish bath (0.5% concentration, commercially available, Duron 3176 from CHT) at 22° C. Tow was first drawn, in a 0.5% concentration finish bath at 75° C. between a 18° C. feed roll running at 30 m/m and heated draw rolls at 80° C. running at 84 m/m, giving a first stage draw ratio of 2.8. Drawn tow was pulled through a steam chest at 100° C. by a downstream heated roll at 165° C. and running at 88.20 m/m. Tow was passed over another set of rolls heated at 165° C. running at 88.20 m/m. Finish (2% concentration, Duron 14+Duron 1105 PE, 30/70 active substance, both by comp. CHT) was sprayed and tow was passed over cooling drum rolls at 25° C., running at 86.44 m/m. Tow entered a steam box at 100° C. prior to entering a 40-mm crimper. Crimper speed was 90.76 m/m. Crimper roller temperature and pressure was 65° C. and 0.8 bar, respectively. Crimped tow was annealed for 4 min at 100° C. in a plate belt drier, Crimped tow was finally cut to produce staple melt spun fiber having the following properties (which were determined using the methods disclosed herein above):

Denier per filament (dpf)=1.28, Coefficient of variation (CV)=15.47%

Tenacity=5.24 g/d, CV=13.05%

Elongation=53.37%, CV=39.14%

Staple length=38 mm

Number of crimp (full-sinus arc)=12.9/inch

Crimp stability=64.08%, CV=17.67%

Finish on yarn=0.26%

Example 28 Melt Spun Staple Fiber Containing Salt-and-Pepper Blends of 50 wt % PTT and 50 wt % Co-PET

A single-screw extruder was used to co-feed polytrimethylene terephthalate and co-PET (from Nan Ya Plastics) in 50:50 weight ratio through a 7590-hole spinneret. Polytrimethylene terephthalate contained 0.3% TiO₂ and had an intrinsic viscosity of 0.96 dL/g. Round cross-section filaments were spun at an extruder throughput of 122.2 kg/h using radial quench. Extruder melt zone temperatures were maintained from 252-263° C. Polymer throughput was 0.268 g/min/hole and feed roll speed was 792 m/m. Spun dpf was nominally 3.4. Spun fibers were collected in cans.

Sixteen (16) cans, totaling 412,896 denier, fed draw-crimp-cut/bale module. A typical cotton count staple process utilizing multi-stage draw, crimper, annealer, and cutter was used to produce staple melt spun fiber. Tow was dipped in a finish bath (0.5% concentration, commercially available, Duron 3176 from CHT) at 22° C. Tow was first drawn, in a 0.5% concentration finish bath at 75° C. between a 18° C. feed roll running at 30 m/m and heated draw rolls at 80° C. running at 87 m/m, giving a first stage draw ratio of 2.9. Drawn tow was pulled through a steam chest at 100° C. by a downstream heated roll at 165° C. and running at 92.22 m/m. Tow was passed over another set of rolls heated at 165° C. running at 90.38 m/m. Finish (2% concentration, Duron 14 +Duron 1105 PE, 30/70 active substance, both by comp. CHT) was sprayed and tow was passed over cooling drum rolls at 25° C., running at 90.38 m/m. Tow entered a steam box at 100° C. prior to entering a 40-mm crimper. Crimper speed was 94.89 m/m. Crimper roller temperature and pressure was 65° C. and 0.8 bar, respectively. Crimped tow was annealed for 4 min at 100° C. in a plate belt drier, Crimped tow was finally cut to produce staple melt spun fiber having the following properties (which were determined using the methods disclosed herein above):

Denier per filament (dpf)=1.31, Coefficient of variation (CV)=10.13%

Tenacity=4.66 g/d, CV=9.72%

Elongation=53.86%, CV=25.47%

Staple length=38 mm

Number of crimp (full-sinus arc)=13.1/inch

Crimp stability=79.51%, CV=9.45%

Finish on yarn=0.20%

Example 29 Melt Spun Staple Fiber Containing Salt-and-Pepper Blends of 50 wt % PTT and 50 wt % Co-PET

A single-screw extruder was used to co-feed polytrimethylene terephthalate and co-PET (from Nan Ya Plastics) in 50:50 weight ratio through a 7590-hole spinneret. Polytrimethylene terephthalate contained 0.3% TiO₂ and had an intrinsic viscosity of 0.96 dL/g. Round cross-section filaments were spun at an extruder throughput of 122.2 kg/h using radial quench. Extruder melt zone temperatures were maintained from 252-263° C. Polymer throughput was 0.268 g/min/hole and feed roll speed was 400 m/m. Spun dpf was nominally 6.4. Spun fibers were collected in cans.

Eight (8) cans, totaling 388,608 denier, fed draw-crimp-cut/bale module. A typical worsted count staple process utilizing multi-stage draw, crimper, annealer, and cutter was used to produce staple melt spun fiber. Tow was dipped in a finish bath (0.5% concentration, commercially available, Duron 3176 from CHT) at 22° C. Tow was first drawn, in a 0.5% concentration finish bath at 75° C. between a 18° C. feed roll running at 30 m/m and heated draw rolls at 80° C. running at 114 m/m, giving a first stage draw ratio of 3.8. Drawn tow was pulled through a steam chest at 100° C. by a downstream heated roll at 165° C. and running at 108.3 m/m. Tow was passed over another set of rolls heated at 165° C. running at 106.1 m/m. Finish (2% concentration, Duron 14 +Duron 1105 PE, 30/70 active substance, both by comp. CHT) was sprayed and tow was passed over cooling drum rolls at 25° C., running at 107.2 m/m. Tow entered a steam box at 100° C. prior to entering a 40-mm crimper. Crimper speed was 112.56 m/m. Crimper roller temperature and pressure was 65° C. and 0.8 bar, respectively. Crimped tow was annealed for 4 min at 100° C. in a plate belt drier, Crimped tow was finally cut to produce multiple cut length staple melt spun fiber having the following properties (which were determined using the methods disclosed herein above):

Denier per filament (dpf)=2.08, Coefficient of variation (CV)=7.47%

Tenacity=4.31 g/d, CV=15.67%

Elongation=67.77%, CV=24.33%

Staple length=multiple cut length, 59.5/79.3/119 mm

Number of crimp (full-sinus arc)=12/inch

Crimp stability=72.11%, CV=12.8%

Finish on yarn=0.09%

Example 30 Melt Spun Staple Fiber Containing Salt-and-Pepper Blends of 20 wt % PBT and 80 wt % Co-PET

A single-screw extruder was used to co-feed CRASTIN® 6130C NC010 polybutylene terephthalate (PBT) having an intrinsic viscosity of 1.15 dL/g and co-PET (from Nan Ya Plastics) in 20:80 weight ratio through a 7590-hole spinneret. Round cross-section filaments were spun at an extruder throughput of 100 kg/h using radial quench. Extruder melt zone temperatures were maintained from 252-263° C. Polymer throughput was 0.220 g/min/hole and feed roll speed was 650 m/m. Spun dpf was nominally 3.18. Spun fibers were collected in cans.

Sixteen (16) cans, totaling 386,179 denier, fed draw-crimp-cut/bale module. A typical cotton count staple process utilizing multi-stage draw, crimper, annealer, and cutter was used to produce staple melt spun fiber. Tow was dipped in a finish bath (0.5% concentration, commercially available, Duron 3176 from CHT) at 22° C. Tow was first drawn, in a 0.5% concentration finish bath at 75° C. between a 18° C. feed roll running at 30 m/m and heated draw rolls at 80 ° C. running at 88.2 m/m, giving a first stage draw ratio of 2.94. Drawn tow was pulled through a steam chest at 100° C. by a downstream heated roll at 165° C. and running at 92.61 m/m. Tow was passed over another set of rolls heated at 165° C. running at 92.61 m/m. Finish (2% concentration, Duron 14 +Duron 1105 PE, 30/70 active substance, both by comp. CHT) was sprayed and tow was passed over cooling drum rolls at 25° C., running at 90.76 m/m. Tow entered a steam box at 100° C. prior to entering a 40-mm crimper. Crimper speed was 95.30 m/m. Crimper roller temperature and pressure was 65° C. and 0.8 bar, respectively. Crimped tow was annealed for 4 min at 100° C. in a plate belt drier, Crimped tow was finally cut to produce staple melt spun fiber having the following properties (which were determined using the methods disclosed herein above):

Denier per filament (dpf)=1.24, Coefficient of variation (CV)=13.51%

Tenacity=5.36 g/d, CV=11.77%

Elongation=47.07%, CV=39.30%

Staple length=40 mm

Number of crimp (full-sinus arc)=10.4/inch

Crimp stability=56.2%, CV=13.9%

Finish on yarn=0.31%

Example 31 Melt Spun Staple Fiber Containing Salt-and-Pepper Blends of 50 wt % PBT and 50 wt % Co-PET

A single-screw extruder was used to co-feed CRASTIN® 6130C NC010 polybutylene terephthalate (PBT) having an intrinsic viscosity of 1.15 dL/g and co-PET (from Nan Ya Plastics) in 50:50 weight ratio through a 7590-hole spinneret. Round cross-section filaments were spun at an extruder throughput of 122.2 kg/h using radial quench. Extruder melt zone temperatures were maintained from 252-263° C. Polymer throughput was 0.268 g/min/hole and feed roll speed was 792 m/m. Spun dpf was nominally 3.42. Spun fibers were collected in cans.

Sixteen (16) cans, totaling 415,324 denier, fed draw-crimp-cut/bale module. A typical cotton count staple process utilizing multi-stage draw, crimper, annealer, and cutter was used to produce staple melt spun fiber. Tow was dipped in a finish bath (0.5% concentration, commercially available, Duron 3176 from CHT) at 22° C. Tow was first drawn, in a 0.5% concentration finish bath at 75° C. between a 18° C. feed roll running at 30 m/m and heated draw rolls at 80° C. running at 87.90 m/m, giving a first stage draw ratio of 2.93. Drawn tow was pulled through a steam chest at 100° C. by a downstream heated roll at 165° C. and running at 94.93 m/m. Tow was passed over another set of rolls heated at 165° C. running at 94.93 m/m. Finish (2% concentration, Duron 14+Duron 1105 PE, 30/70 active substance, both by comp. CHT) was sprayed and tow was passed over cooling drum rolls at 25° C., running at 93.03 m/m. Tow entered a steam box at 100° C. prior to entering a 40-mm crimper. Crimper speed was 97.69 m/m. Crimper roller temperature and pressure was 65° C. and 0.8 bar, respectively. Crimped tow was annealed for 4 min at 100° C. in a plate belt drier, Crimped tow was finally cut to produce staple melt spun fiber having the following properties (which were determined using the methods disclosed herein above):

Denier per filament (dpf)=1.17, Coefficient of variation (CV)=13.6%

Tenacity=5.48 g/d, CV=12.38%

Elongation=39.74%, CV=27.57%

Staple length=40 mm

Number of crimp (full-sinus arc)=11.8/inch

Crimp stability=60.23%, CV=8.30%

Finish on yarn=0.24%

Example 32 40s Ne Spun Yarn Containing 100% Melt Spun Fiber

Spun yarn was prepared using melt spun staple fiber from Example 28 according to the procedure of Example 5 except with the following differences:

The linear density of the final sliver was 4.75 g/meter and the Unevenness % was 1.75.

The roving hank was 1.2 s Ne.

In the step of drafting the roving, the twist multiplier/twist per inch was 3.6/22.6, the Traveler size was 4/0 M1HO, and the spindle speed was 16500 rpm.

The spun yarn was wound onto a cone at 1500 meters/min. Properties of the spun yarn are given in Table 13. Properties of the spun yarns of this and the following Examples were determined using the methods disclosed herein above.

Example 33 40s Ne Spun Yarn Containing 100% Melt Spun Fiber

Spun yarn was prepared using melt spun staple fiber from Example 27 according to the procedure of Example 32. Properties of the spun yarn are given in Table 13.

Example 34 40s Ne Spun Yarn Containing 100% Melt Spun Fiber

Spun yarn was prepared using melt spun staple fiber from Example 31 according to the procedure of Example 32. Properties of the spun yarn are given in Table 13.

Example 35 40s Ne Spun Yarn Containing 100% Melt Spun Fiber

Spun yarn was prepared using melt spun staple fiber from Example 30 according to the procedure of Example 32. Properties of the spun yarn are given in Table 13.

Example 36 40s Ne Spun Yarn Containing 40/60 (wt/wt) Melt Spun Fiber/Cotton

Spun yarn was prepared using melt spun staple fiber from Example 28 and cotton (Shankar 6 variety Indian cotton commercially obtained from north Indian states). The cotton staple had average length of 31 mm and linear density of 4.1 microgram/inch (1.6 microgram/cm). The spun yarn was made according to the procedure of Example 32. Properties of the spun yarn are given in Table 13.

Example 37 40s Ne Spun Yarn Containing 40/60 (wt/wt) Melt Spun Fiber/Cotton

Spun yarn was prepared using melt spun staple fiber from Example 27 and cotton (Shankar 6 variety Indian cotton commercially obtained from north Indian states). The cotton staple had average length of 31 mm and linear density of 4.1 microgram/inch (1.6 microgram/cm). The spun yarn was made according to the procedure of Example 8. Properties of the spun yarn are given in Table 13.

Example 38 40s Ne Spun Yarn Containing 40/60 (wt/wt) Melt Spun Fiber/Cotton

Spun yarn was prepared using melt spun staple fiber from Example 31 and cotton (Shankar 6 variety Indian cotton commercially obtained from north Indian states). The cotton staple had average length of 31 mm and linear density of 4.1 microgram/inch (1.6 microgram/cm). The spun yarn was made according to the procedure of Example 8. Properties of the spun yarn are given in Table 13.

Example 39 40s Ne Spun Yarn Containing 40/60 (wt/wt) Melt Spun Fiber/Cotton

Spun yarn was prepared using melt spun staple fiber from Example 30 and cotton (Shankar 6 variety Indian cotton commercially obtained from north Indian states). The cotton staple had average length of 31 mm and linear density of 4.1 microgram/inch (1.6 microgram/cm). The spun yarn was made according to the procedure of Example 8. Properties of the spun yarn are given in Table 13.

Example 40 40s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Tencel

Spun yarn was prepared using melt spun staple fiber from Example 28 and commercially-obtained Tencel® staple fiber (Lenzing). The Tencel® staple had average length of 40 mm and denier of 1.2 D. The spun yarn was made according to the procedure of Example 10. Properties of the spun yarn are given in Table 13.

Example 41 40s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Tencel

Spun yarn was prepared using melt spun staple fiber from Example 27 and commercially-obtained Tencel® staple fiber (Lenzing). The Tencel® staple had average length of 40 mm and denier of 1.2 D. The spun yarn was made according to the procedure of Example 10. Properties of the spun yarn are given in Table 13.

Example 42 40s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Tencel

Spun yarn was prepared using melt spun staple fiber from Example 31 and commercially-obtained Tencel® staple fiber (Lenzing). The Tencel® staple had average length of 40 mm and denier of 1.2 D. The spun yarn was made according to the procedure of Example 10. Properties of the spun yarn are given in Table 13.

Example 43 40s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Tencel

Spun yarn was prepared using melt spun staple fiber from Example 30 and commercially-obtained Tencel® staple fiber (Lenzing). The Tencel® staple had average length of 40 mm and denier of 1.2 D. The spun yarn was made according to the procedure of Example 10. Properties of the spun yarn are given in Table 13.

Example 44 2/68s Nm Spun Yarn Containing 45/55 Wool/Melt Spun Staple Fiber

Spun yarn was made using the worsted spinning system, according to the following procedure.

Melt spun staple fiber from Example 29 was used to prepare the spun yarn of Example 44. The melt spun staple fiber, 2.5 denier and of 84 mm average length, was taken and converted to sliver in cotton card spinning system as per regular process of carding normally used in spinning mills. This sliver was blended with wool top (Australian Merino of 20.5 micron, 68 mm average mean length) and spun in worsted spinning system in 45/55 (wt/wt) wool/melt spun staple fiber blend proportion. The nominal count spun for the spun yarn was 2/68s Nm.

In Table 13, the reported Boiling Water Shrinkage values were obtained according to method ASTM D2259 and using a 1 kg weight.

TABLE 13 Properties of the Spun Yarns of Example 32 Through Example 44 Boiling Water Number of Shrinkage Melt Spun Breaking Imperfections (BWS) (%), Yarn Staple from Tenacity Elongation U (per km Hairiness at 1 kg dead Example Yarn Description Example (cN/Tex) (%) (%) of yarn) Index weight 32 40s Ne 100% melt spun 28 22.3 17.7 12.0 231 4.86 15.13 staple 33 40s Ne 100% melt spun 27 25.4 13.5 11.3 46 4.79 8.57 staple 34 40s Ne 100% melt spun 31 24.2 12.6 13.3 548 4.98 8.00 staple 35 40s Ne 100% melt spun 30 31.4 14.4 10.7 85 4.7 6.50 staple 36 40s Ne 40/60 melt spun 28 12.11 4.3 13.3 659 6.07 10.27 staple/cotton 37 40s Ne 40/60 melt spun 27 10.8 4.6 14.4 1188 6.29 6.84 staple/cotton 38 40s Ne 40/60 melt spun 31 13.8 5.7 13.0 595 6.22 6.34 staple/cotton 39 40s Ne 40/60 melt spun 30 14.9 5.3 13.4 588 5.84 5.07 staple/cotton 40 40s Ne 40/60 melt spun 28 18.2 8.0 11.1 219 5.26 7.36 staple/Tencel ® 41 40s Ne 40/60 melt spun 27 22.1 8.8 11.4 195 5.43 5.47 staple/Tencel ® 42 40s Ne 40/60 melt spun 31 25.7 9.7 10.1 126 — 4.88 staple/Tencel ® 43 40s Ne 40/60 melt spun 30 23.7 9.0 11.7 475 5.93 3.06 staple/Tencel ® 44 2/68s Nm 45/55 29 17.0 38.9 12.7 109 — 4.82 Wool/melt spun staple

The results in Table 13, as compared to the results in Table 4 and 5, show that the tenacities of spun yarns incorporating salt-and-pepper blended PET/PTT 50:50 melt spun staple are similar to those of spun yarns incorporating compounded PET/PTT 50:50 melt spun staple. Boiling water shrinkage percent is higher for spun yarns incorporating salt-and-pepper PET/PTT 50:50 melt spun staple as compared to that of spun yarns incorporating compounded PET/PTT 50:50 melt spun staple. All other properties were found to be similar.

Woven Fabric Examples

The spun yarns of Examples 32 through 44 were used to make woven fabrics as indicated in Table 14. Plain weave (1/1) shirting fabrics were made using the spun yarns disclosed herein as the warp and weft (fill) yarns. For each woven fabric, the same yarn was used in both the warp and the weft. Fabric evaluation results are presented in Tables 15 and 16. Results are reported for finished fabric unless otherwise noted. Fabric properties of this and the following Examples were determined using the methods disclosed herein above.

Example 45

Spun yarn from Example 32 was used as the warp and as the weft to prepare a plain weave (1/1) shirting fabric. The warp yarns were sized before beaming using a CCI single end sizing machine using Elvanol-T25 PVA sizing agent. Using a warper at 350 m/min, a final beam with 1680 ends, a width of 18 inches, and end lengths of 3.5 meters was prepared. With the following denting plan:

Drawing: 4 shafts

Drawing type (straight drawing (1, 2, 3, &4)

Denting: 2 ends/dent

Reed count: 84 dents/2 inch

1/1 plain fabric was woven on a CCI sample loom with loom speed at 40 picks/minute. The pick value was set at 49 picks/inch.

The greige fabric was desized on an RBE lab Jigger machine as follows. The fabric sample was loaded into the jigger filled with water (2 L), NaOH (2 gpl), and wetting agent; Levocol CESR (wetting agent) was added (5 gpl) and the bath temperature was raised to 90° C. The fabric was run in the bath for 60 mins, then the bath was drained, refilled with fresh water, and the temperature of the bath was raised to 85° C. The fabric was hot water washed for 15 min, and the bath was drained. The bath was again filled with water and the fabric was run through it for 15 min (cold water wash). Bath was drained, filled with water, and neutralized by adding acetic acid (1 gpl); fabric was run for 15 min in this bath. Afterwards, the bath was drained, refilled with fresh water, and the fabric run in cold water bath for 15 min. The fabric was then unloaded from the jigger and dried in atmospheric conditions, then heat set in an RBE stenter at 160° C. for 45 seconds.

The fabric was then dyed with a mixture of disperse dyes using the following time and temperature profile: heat to 70° C. and hold for 10 minutes, then raise temperature 1.5° C./min to 130° C. and hold for 30 minutes, then decrease temperature 1.5° C./min to 70° C. and drain. Post dyeing, the fabric was given a reduction cleaning with Hydros and NaOH (2 gpl each), 90° C. for 20 min. The fabric was then washed with cold water for 10 minutes, contacted with acetic acid (2 gpl) for 15 minutes, then washed with cold water for 10 minutes. The dyed fabric was padded with finishing agent (softener), then heat set at 160° C. for 45 seconds in an RBE lab stenter.

Fabric construction is shown in Table 14. Wicking test results were 100%. Other fabric properties are presented in Tables 15 and 16.

Example 46

Spun yarn from Example 33 was used as the warp and as the weft to prepare a plain weave shirting fabric as per procedure given in Example 45.

Fabric construction is shown in Table 14. Wicking test results were 100%. Other fabric properties are presented in Tables 15 and 16.

Example 47

Spun yarn from Example 34 was used as the warp and as the weft to prepare a plain weave shirting fabric as per procedure given in Example 45. Fabric construction is shown in Table 14. Wicking test results were 100%. Other fabric properties are presented in Tables 15 and 16.

Example 48

Spun yarn from Example 35 was used as the warp and as the weft to prepare a plain weave shirting fabric. as per procedure given in Example 45. Fabric construction is shown in Table 14. Wicking test results were 100%. Other fabric properties are presented in Tables 15 and 16.

Example 49

Spun yarn from Example 36 was used as the warp and as the weft to prepare a plain weave shirting fabric according to the procedure of Example 45 but with the following exceptions. The pick value was set at 58 picks/inch on the loom. The greige fabric was desized and bleached in a Jigger machine, heat set in a stenter, then dyed with a mixture of disperse dyes, then additionally dyed with a reactive dye under cotton dyeing conditions. Fabric construction is shown in Table 14. Wicking test results were 100%. Other fabric properties are presented in Tables 15 and 16.

Example 50

Spun yarn from Example 37 was used as the warp and as the weft to prepare a plain weave shirting fabric according to the procedure of Example 49 but with the following exceptions. The greige fabric was desized and bleached in a Jigger machine, heat set in a stenter, then dyed with a mixture of disperse dyes, then additionally dyed with a reactive dye under cotton dyeing conditions. Fabric construction is shown in Table 14. Wicking test results were 100%. Other fabric properties are presented in Tables 15 and 16.

Example 51

Spun yarn from Example 38 was used as the warp and as the weft to prepare a plain weave shirting fabric according to the procedure of Example 49 but with the following exceptions. The greige fabric was desized and bleached in a Jigger machine, heat set in a stenter, then dyed with a mixture of disperse dyes, then additionally dyed with a reactive dye under cotton dyeing conditions. Fabric construction is shown in Table 14. Wicking test results were 100%. Other fabric properties are presented in Tables 15 and 16.

Example 52

Spun yarn from Example 39 was used as the warp and as the weft to prepare a plain weave shirting fabric according to the procedure of Example 49 but with the following exceptions. The greige fabric was desized and bleached in a Jigger machine, heat set in a stenter, then dyed with a mixture of disperse dyes, then additionally dyed with a reactive dye under cotton dyeing conditions.

Fabric construction is shown in Table 14. Wicking test results were 100%. Other fabric properties are presented in Tables 15 and 16.

Example 53

Spun yarn from Example 40 was used as the warp and as the weft to prepare a plain weave shirting fabric according to the procedure of Example 49, except that no peroxide killer was used at the end of the bleaching step. The pick value was set at 65 picks/inch on the loom.

Fabric construction is shown in Table 14. Wicking test results were 100%. Other fabric properties are presented in Tables 15 and 16.

Example 54

Spun yarn from Example 41 was used as the warp and as the weft to prepare a plain weave shirting fabric according to the procedure of Example 53. Fabric construction is shown in Table 14. Wicking test results were 100%. Other fabric properties are presented in Tables 15 and 16.

Example 55

Spun yarn from Example 42 was used as the warp and as the weft to prepare a plain weave shirting fabric according to the procedure of Example 53. Fabric construction is shown in Table 14. Wicking test results were 100%. Other fabric properties are presented in Tables 15 and 16.

Example 56

Spun yarn from Example 42 was used as the warp and as the weft to prepare a plain weave shirting fabric according to the procedure of Example 53.

Fabric construction is shown in Table 14. Wicking test results were 100%. Other fabric properties are presented in Tables 15 and 16.

Example 57

Spun yarn from Example 34 was used as the warp and as the weft to prepare a suiting fabric of 2/1 twill construction. The warp yarns were sized before beaming using a CCI single end sizing machine using Elvanol-T25 PVA sizing agent and a softener. Using a warper at 350 m/min, a final beam with 1518 ends, a width of 18 inches, and end lengths of 3.5 meters was prepared. With the following denting plan:

Drawing: 3 shafts

Drawing type (straight drawing (1, 2, &3)

Denting: 3 ends/dent

Reed count: 51.5 dents/2 inch

2/1 RHT twill fabric was woven on a CCI sample loom with loom speed at 40 picks/minute. The pick value was set at 53 picks/inch. Greige fabric of 2 m length and 48.3 cm width was obtained.

The greige fabric was desized in a Jigger machine using a procedure similar to that of Example 49, except that Albatex AD was used in conjunction with Levocol CESR. The fabric was then subjected to a hot water wash (85° C. for 15 minutes), a cold water wash (15 minutes), a neutralization step with acetic acid (15 minutes), and another cold water wash (15 minutes). The fabric was allowed to dry flat in atmospheric conditions, then heat set at 170° C. for 45 seconds.

The fabric was then dyed with a mixture of disperse dyes using the following time and temperature profile: heat to 70° C. and hold for 10 minutes, then raise temperature 1.5° C./min to 130° C. and hold for 30 minutes, then decrease temperature 1.5° C./.min to 70° C. and drain. The fabric was given a reduction cleaning with Hydros and NaOH (1 gpl each), 90° C. for 20 min. The fabric was then washed with cold water for 10 minutes, contacted with acetic acid (2 gpl) for 15 minutes, then washed with cold water for 10 minutes.

The fabric was then dyed with a mixture of acid dyes using the following time and temperature profile: heat to 70° C. and hold for 10 minutes, then raise temperature 1.5° C./min to 98° C. and hold for 45 minutes, then decrease temperature 1.5° C./min to 70° C. and drain. The fabric was washed in cold water (10 minutes), treated with acetic acid (1 gpl for 15 minutes), subjected to a hot soaping with Albatex AD (90° C. for 15 minutes), washed with hot water (85° C. for 15 minutes), washed with cold water (10 minutes), then contacted with Levocol HCF (0.5 gpl) at 50° C. for 20 minutes to fix the dye.

The fabric was decatized in an autoclave (130° C. for 3 minutes) then padded with finishing agent, Levofin HYP-5gp1 Levocol PNLI-10gpl, before being heat set at 160° C. for 45 seconds in a lab stenter, and then decatized again in an autoclave (130° C. for 3 minutes).

The greige and finished fabrics were evaluated. The fabric construction and testing results are given in Tables 14, 15, and 16. Wicking test results were 100%.

TABLE 14 Woven Fabric Construction for Fabric Examples 45-57 Spun Yarn Fabric Details Fabric Construction Fabric Weight Fabric from (same yarn in (ends/inch * pick/inch) (g/m²) Example Example warp and weft) Greige Finished Greige Finished 45 32 Shirting, plain 92*52 110*71 93 145 46 33 Shirting, plain 90*52  98*62 92 122 47 34 Shirting, plain 90*52 102*62 91 113 48 35 Shirting, plain 90*54  96*61 100 124 49 36 Shirting, plain 93*62 106*78 95 130 50 37 Shirting, plain 92*60  98*72 83 102 51 38 Shirting, plain 92*62 102*76 98 117 52 39 Shirting, plain 91*61  98*71 95 109 53 40 Shirting, plain 92*66 110*79 95 127 54 41 Shirting, plain 92*69 102*81 95 115 55 42 Shirting, plain 92*67 101*81 102 120 56 43 Shirting, plain 92*69 102*79 104 123 57 44 Suiting, twill, 2/1 RHT 81*55  93*73 163 245

TABLE 15 Woven Fabric Evaluation Results (First Half) for Fabric Examples 45-57 Dimensional Tear Tensile Breaking Abrasion Stability Strength Strength Elongation Weight Fabric (%) (g) (kgf) (%) Thickness Pill Loss Example warp weft warp weft warp weft warp weft (mm) Rating Rating (%) 45 −0.8 −1.5 >6400 5150 29.5 18.9 100.9 71.3 0.30 3-4 2 0.18 46 −0.9 −1.3 3840 3968 28.2 24.9 71.8 45.4 0.27 2-3 1 0.31 47 −1.0 −1.2 3264 2432 27.9 22.8 61.3 45.2 0.26 3 1 0.52 48 −1.1 −1.2 4160 2944 27.4 25.5 67.0 41.9 0.28 3 1 0.06 49 −0.7 −1.6 1056 896 16.1 11.7 43.3 37.2 0.31 3 4 0.93 50 −0.7 −0.7 896 704 17.9 9.6 27.7 19.4 0.29 2-3 3 2.06 51 −1.2 −0.9 1154 768 20.8 13.7 33.7 24.2 0.28 3 3-4 1.65 52 −1.5 −0.8 960 896 19.6 11.7 27.5 19.3 0.28 3 3 1.25 53 −1.5 −1.9 1920 1600 17.0 13.0 46.1 27.7 0.32 2-3 3 3.53 54 −1.6 −1.2 832 768 20.8 17.0 26.4 21.7 0.28 2 2-3 3.29 55 −1.1 −1.6 960 768 25.9 19.5 32.6 21.6 0.27 2-3 3 2.19 56 −1.9 −1.5 960 960 21.8 18.7 27.2 19.7 0.26 2-3 3 2.32 57 −2.1 −1.6 3328 1920 24.4 18.5 115.7 71.1 0.58 5 4 4.36

TABLE 16 Woven Fabric Evaluation Results (Second Half) for Fabric Examples 45-57 Drape Shrinkage, Area Greige Stretch & Recovery of Drape to Finishing Recovery Recovery Colorfastness Colorfastness to Washing Fabric Drape Coeff. Warp Weft Stretch in 1 min in 60 mins to Rubbing Shade Example (cm²) (%) (%) (%) (%) (%) (%) Dry Wet Change Acetate Cotton Nylon Polyester Acrylic Wool 45 202.5 21.6 −22.7 −15.1 3.8 76.7 80 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 46 179.4 15.4 −16.1 −9.3 4 68.8 81.3 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 47 175.6 14.3 −16.2 −10.0 3 75.0 83.3 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 48 191.0 18.5 −17.2 −7.4 2.5 70.0 80.0 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 49 266.6 39.0 −23.4 −13.3 6 58.3 70.8 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 50 221.7 26.9 −13.0 −8.3 6.5 57.7 69.2 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 51 215.3 25.1 −12.0 −7.0 7.5 53.3 63.3 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 52 232.0 29.6 −11.2 −7.1 6.3 60.0 76.0 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 53 219.2 26.2 −20.5 −10.9 8.6 58.0 73.9 4-5 4 4-5 4-5 4 4 4-5 4-5 4-5 54 193.5 19.2 −15.2 −7.8 6 58.3 75.0 4-5 4 4-5 4-5 4 4 4-5 4-5 4-5 55 192.3 18.9 −16.1 −6.7 6.5 57.7 73.1 4-5 4 4-5 4-5 4 4 4-5 4-5 4-5 56 194.8 19.6 −13.0 −6.2 6 66.7 83.3 4-5 4 4-5 4-5 4 4 4-5 4-5 4-5 57 214.0 24.8 −25.9 −17.2 7 64.3 82.1 4-5 4 4-5 4 4-5 3-4 4-5 4-5 3-4

The results shown in Tables 14, 15, and 16, and also previous Tables 6, 7, and 8, demonstrate that the spun yarns disclosed herein can be used to make woven fabrics having desirable properties.

Circular Knit Fabric Examples

The spun yarns of Examples 32 through 44 were used as the knitting yarn to make circular knit fabrics as indicated in Table 17. For all circular knit fabrics made using 40s Ne count yarns, the machine gauge was 24″. Fabric evaluation results are presented in Table 18. Results are reported for finished fabric unless otherwise noted.

Examples 58, 59, 60, and 61

Spun yarns from Examples 32, 33, 34, and 35 were each used to prepare circular knit fabrics on a Mesdan lab knitter. The greige fabric was heat set in an RBE stenter at 160° C. for 45 seconds, then scoured in an HTHP Beaker dyeing machine using the following procedure. The fabric was scoured at 90° C. for 60 minutes with NaOH (2 gpl) and wetting agent Levocol CESR (5 gpl) added. The fabric was washed at 85° C. for 15 minutes, then with cold water for 15 minutes, then with a neutralization solution containing acetic acid (1 gpl) for 15 minutes, followed by another cold water wash for 15 minutes.

The scoured fabrics were then dyed in the same machine with a mixture of disperse dyes using the following time and temperature profile: heat to 70° C. and hold for 10 minutes, then raise temperature 1.5° C./min to 130° C. and hold for 30 minutes, then decrease temperature 1.5° C./min to 70° C. and drain. Post dyeing, the fabric was given a reduction cleaning with Hydros and NaOH (2 gpl each), 90° C. for 20 min. The fabric was then washed with cold water for 10 minutes, neutralized with acetic acid (2 gpl) for 15 minutes, then washed again with cold water for 10 minutes. The dyed fabric was padded with finishing agent (softener), then heat set at 160° C. for 45 seconds in a lab stenter. Fabrics construction and testing results are presented in Tables 17 and 18. Wicking test results were 100% for all the fabrics

Examples 62, 63, 64, and 65

Spun yarns from Example 36, 37, 38, and 39 were each used to prepare circular knit fabrics on a Mesdan lab knitter following the procedure of Example 58, except that after dyeing with the disperse dyes, the fabric was dyed in the same machine with a reactive dye mixture to which salt (60 gpl) was added, using the following time and temperature profile: heat to 60° C. and hold for 30 minutes, then add soda ash (15 gpl) and hold for 30 minutes before draining. The fabric was then washed with cold water for 10 minutes, washed with acetic acid (1 gpl) for 15 minutes, then given a hot soaping with Albatex AD (2 gpl) during which the temperature was raised to 90° C. and held for 15 minutes. The fabric was then washed with hot water (85° C.) for 15 minutes, and then with cold water for 10 minutes. The dye was fixed with Levocol HCF (0.5 gpl) during which the temperature was raised to 50° C. and held for 20 minutes. The dyed fabric was padded with finishing agent then heat set at 160° C. for 45 seconds in a lab stenter. Fabric construction and testing results are presented in Tables 17 and 18. Wicking test results were 100% for all the fabrics

Examples 66, 67, 68, and 69

Spun yarns from Example 40, 41, 42, and 43 were each used to prepare circular knit fabrics on a Mesdan lab knitter following the procedure of Example 18, except with a different mixture of disperse dyes and a different mixture of reactive dyes and no peroxide killer was used at the end of the bleaching step. Fabric construction and testing results are presented in Tables 17 and 18. Wicking test results were 100% for all the fabrics

Example 70

Spun yarn from Example 44 was used to prepare a circular knit fabric on a Mesdan lab knitter following the procedure of Example 14. The fabric was dyed and finished following the example of 57. Fabrics construction and testing results are presented in Tables 17 and 18. Wicking test results were 100% for all the fabrics

TABLE 17 Circular Knit (CK) Fabric Construction and Evaluation Results for Examples 58 Through 70 Spun Abrasion Yarn Fabric Weight Dimensional Stability Bursting Weight Colorfastness Fabric from (g/m²) (%) Strength Pill Loss Thickness to Rubbing Example Example Greige Finished Lengthwise Widthwise (kg/cm²) Rating Rating (%) (mm) Dry Wet 58 32 112 202 −1.1 −1.2 6.7 3 1-2 0.23 0.41 4-5 4-5 59 33 110 173 −1.7 −1.9 8.5 1-2 1 0.36 0.40 4-5 4-5 60 34 113 148 −1.6 −1.3 8.5 1-2 1 0.28 0.39 4-5 4-5 61 35 106 188 −1.1 −1.2 6.7 2-3 1 0.14 0.40 4-5 4-5 62 36 105 159 −1.8 −1.6 5.1 4 1-2 1.11 0.50 4-5 4-5 63 37 98 133 −1.0 1.0 4.8 3-4 1 1.26 0.42 4-5 4-5 64 38 105 138 −1.4 −1.1 5.4 3-4 1 1.69 0.43 4-5 4-5 65 39 98 147 −1.5 −1.7 6.0 3-4 1 1.27 0.42 4-5 4-5 66 40 105 171 −1.2 −1.7 5.7 3-4 2 2.24 0.50 4-5 4-5 67 41 102 144 −0.9 −1.2 5.3 3 2 2.07 0.42 4-5 4-5 68 42 105 149 −1.4 −1.7 5.0 2-3 2 1.79 0.41 4-5 4-5 69 43 106 147 −1.2 −1.6 5.6 2 2 3.04 0.42 4-5 4-5 70 44 198 320 −0.9 −0.7 6.4 4 2-3 2.93 0.64 4-5 4

TABLE 18 Circular Knit (CK) Fabric Evaluation Results Continued for Examples 58 Through 70 Stretch (%) and Recovery (“Recov”) (%) Lengthwise Widthwise Recov. Recov. Recov. Recov. Recov. Recov. Colorfastness to Washing Fabric in 1 in 30 in 60 in 1 in 30 in 60 Shade Example Stretch min min min Stretch min min min Change Acetate Cotton Nylon Polyester Acrylic Wool 58 20 86.9 92.1 92.1 93.0 91.5 94.3 95.5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 59 33 95.2 96.8 98.4 123.0 95.7 97.4 97.9 4-5 4-5 4-5 4-5 4-5 4-5 4-5 60 39 89.2 91.9 93.3 127.0 88.4 93.4 94.2 4-5 4-5 4-5 4-5 4-5 4-5 4-5 61 36 91.2 94.2 95.6 133.0 94.0 96.4 97.2 4-5 4-5 4-5 4-5 4-5 4-5 4-5 62 55 81.1 82.8 86.6 114.0 83.9 86.8 87.7 4-5 4-5 4-5 4-5 4-5 4-5 4-5 63 56 81.6 83.1 87.7 137.0 87.7 89.7 91.0 4-5 4-5 4-5 4-5 4-5 4-5 4-5 64 57 80.5 82.6 87.1 126.0 86.1 87.9 89.1 4-5 4-5 4-5 4-5 4-5 4-5 4-5 65 55 78.0 81.5 89.5 131.0 86.2 88.3 89.2 4-5 4-5 4-5 4-5 4-5 4-5 4-5 66 47 79.9 84.3 87.7 110.0 84.4 86.6 87.7 4-5 4-5 4-5 4-5 4-5 4-5 4-5 67 51 79.4 85.6 88.7 131.0 87.2 89.5 90.5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 68 50 82.1 88.4 90.5 127.0 86.6 88.9 89.7 4-5 4-5 4-5 4-5 4-5 4-5 4-5 69 47 84.3 92.2 93.3 135.0 87.0 88.9 89.7 4-5 4-5 4-5 4-5 4-5 4-5 4-5 70 37 91.5 94.3 95.8 43.0 92.7 95.1 96.3 4-5 4 4-5 3-4 4-5 4-5 3-4

The results shown in Tables 17 and 18, and also previous Tables 9 and 10, demonstrate that the spun yarns disclosed herein can be used to make circular knit fabrics having desirable properties. 

What is claimed is:
 1. A spun yarn comprising: melt spun staple fiber comprising a first polymer comprising poly(trimethylene terephthalate) or poly(butylene terephthalate) and a second polymer comprising poly(ethylene terephthalate) or Co-PET, wherein Co-PET is a poly(ethylene terephthalate) copolymer comprising isophthalic acid monomer; and wherein the first polymer comprises poly(trimethylene terephthalate) and the weight ratio of the poly(trimethylene terephthalate) to the second polymer is in the range of from about 80:20 to about 10:90; or the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of from about 90:10 to about 10:90.
 2. The spun yarn of claim 1, wherein the first polymer comprises poly(trimethylene terephthalate) and the second polymer comprises poly(ethylene terephthalate).
 3. The spun yarn of claim 1, wherein the first polymer comprises poly(trimethylene terephthalate) and the second polymer comprises Co-PET, and the Co-PET contains from about 0.5 mole percent to about 10 mole percent isophthalic acid monomer, based on the total copolymer composition.
 4. The spun yarn of claim 1, wherein the first polymer comprises poly(butylene terephthalate) and the second polymer comprises poly(ethylene terephthalate).
 5. The spun yarn of claim 1, wherein the first polymer comprises poly(butylene terephthalate) and the second polymer comprises Co-PET, and the Co-PET contains from about 0.5 mole percent to about 10 mole percent isophthalic acid monomer, based on the total copolymer composition.
 6. The spun yarn of claim 3 or claim 5, wherein the spun yarn has a boil off shrinkage of at least about 6% as determined according to ASTM D2259.
 8. The spun yarn of claim 1, wherein the weight ratio of the poly(trimethylene terephthalate) or the poly(butylene terephthalate) to the second polymer is in the range of 70:30 to 30:70.
 9. The spun yarn of claim 1, further comprising a second staple fiber in an amount from about 5 wt % to about 95 wt %, based on the total weight of the spun yarn.
 10. The spun yarn of claim 9, wherein the second staple fiber comprises polylactic acid, acrylic, nylon, olefin, acetate, rayon, polyester, cotton, linen, wool, angora, mohair, alpaca, cashmere, or a mixture thereof.
 11. The spun yarn of claim 10, wherein the second staple fiber comprises cotton or wool.
 12. A fabric comprising the spun yarn of claim
 1. 13. The fabric of claim 12, wherein the first polymer comprises poly(trimethylene terephthalate) and the second polymer comprises poly(ethylene terephthalate).
 14. The fabric of claim 12, wherein the first polymer comprises poly(trimethylene terephthalate) and the second polymer comprises Co-PET.
 15. The fabric of claim 12, wherein the first polymer comprises poly(butylene terephthalate) and the second polymer comprises poly(ethylene terephthalate).
 16. The fabric of claim 12, wherein the first polymer comprises poly(butylene terephthalate) and the second polymer comprises Co-PET.
 17. The fabric of claim 12, wherein the fabric has at least one of: i) better abrasion resistance as determined according to ASTM D4966 Standard Test Method; ii) higher pill rating values as determined according to ASTM D4970 Standard Test Method; or iii) greater bulk as determined according to ASTM D1777 Standard Test Method; than a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.
 18. The fabric of claim 12, wherein the fabric is a woven fabric having a warp and a weft, and the warp, the weft, or both the warp and the weft each comprise the spun yarn of claim
 1. 19. The fabric of claim 12, wherein the fabric is a knit fabric.
 20. The fabric of claim 19, wherein the fabric has higher recovery as determined according to Method BS 4294 than a knit fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.
 21. An article comprising the fabric of claim
 12. 